BRPI0910119A2 - catalyst device and manufacturing method of catalyst device - Google Patents

Abstract

CATALYST DEVICE AND METHOD OF MANUFACTURING CATALYST DEVICE. The present invention relates to a catalyst device that contains a catalyst carrier in an outer cylinder, the catalyst carrier is attached to the outer cylinder with a simple structure. A catalyst device (1) which is provided with a catalyst carrier (10), which carries a catalyst having a discharge purification function, an external cylinder (13) containing the catalyst carrier (10) and a holding mat (12) arranged between the catalyst carrier (10) and the outer cylinder (13), in which a high friction portion (14) is arranged between the catalyst carrier (10) and the outer cylinder (13) in order to prevent movement of the retaining belt (12).

Description

Patent Specification Report for "CATALYSTING DEVICE AND METHOD OF MANUFACTURING CATALYSTING DEVICE". Technical field 5 The present invention relates to a catalyst device that purifies the exhaust gas of an internal combustion engine, a method of manufacturing a catalyst device and a retaining structure for a catalyst carrier

4 Prior Art 10 As a catalyst device that purifies the exhaust gas - from an engine or similar, a catalyst containing a catalyst carrier manufactured in a cylindrical shape and made of ceramic in the outer cylinder and having a corrugated plate for the damper, disposed between the outer cylinder and the catalyst carrier (see Patent Document 1, for example). Also, a catalyst converter containing a catalyst carrier having a honeycomb structure in the outer cylinder is known (see Patent Document 2 for example). With the configuration described in Patent Document 2, a ceramic mat as a suspension pad material is wound around the catalyst carrier, which is contained in the outer cylinder.

Patent Document 1: JP-A-H02-43955 Patent Document 2: JP-A-H11-33410 Summary of the invention 25 Technical problem In the catalyst device of Patent Document 1, for providing a barrier component in contact with an end face on the downstream side of the exhaust gas in the catalyst carrier, the catalyst carrier is prevented from moving to the downstream side 30 of the exhaust gas by the discharge gas pressure.

However, if separate components, such as a barrier element and so on, are provided, the number of components is increased and the structure becomes complicated. In this way, a simpler fixation of the catalyst carrier has been researched. The present invention was created in view of the above circumstances and aims, in a catalyst device containing a catalyst carrier 5 in the outer cytometer, to secure the catalyst carrier to the outer cylinder with a simple structure. Solution to the problem In order to solve the problem, the present invention provides "a catalyst device that includes a catalyst carrier that carries a catalyst having a discharge purification function, a

W outer cylinder containing the catalyst carrier and a mat arranged between the catalyst carrier and the outer cylinder, characterized in that a portion of frictional friction is disposed between the catalyst carrier and the outer cylinder in order to prevent movement of at least one between the catalyst carrier or the belt. According to this configuration, since the high friction portion that prevents the movement of at least one between the catalyst carrier or the belt is disposed between the catalyst carrier and the outer cylinder, the catalyst carrier is attached to the outer cylinder 20 by friction in the high friction portion. That is, the catalyst carrier is attached to the outer cylinder at least by the high friction portion between the catalyst carrier and the belt or the high friction portion between the belt and the outer cylinder. In this way, the catalyst carrier can be fixed to the outer cylinder with a simple structure. 25 Also, the high friction portion can be arranged in a region that includes at least one of a portion in contact with a portion of the belt end or its proximity to the inner face of the outer cylinder. In this case, provided that the portion of high friction with a higher friction coefficient is arranged on the inner face of the outer cylinder, the mat is fixed on the inner face of the outer cylinder by friction with the high friction portion. Therefore, the catalyst carrier can be attached to the outer cylinder by the friction between the belt and the outer cylinder and the catalyst carrier can be attached to the outer cylinder by a simple structure.

And since the end portion of the mat is in contact with the high friction portion on the inner face of the outer cylinder or since the mat and the high friction portion are brought into contact with each other if the mat is to be displaced by the pressure of the exhaust gas, the catalyst carrier can be fixed on the outer cylinder by the friction between the belt and the outer cylinder.

Therefore, the catalyst carrier can be attached to the

"outer cylinder by a simple structure. 10 Also, one end of the outer cylinder located at the downstream side with respect to the discharge gas flow can be extended more than the end portion of the mat, and the top portion friction can be formed in that extended portion.

In this case, if the conveyor must be moved to the side downstream of the exhaust gas, the conveyor is placed in contact with the high friction portion disposed on the downstream side of the exhaust gas and is stopped by friction with the high friction portion.

Therefore, the catalyst carrier can be attached to the outer cylinder by the friction between the belt and the outer cylinder. 20 Also, since the high friction portion is disposed at the end on the side downstream of the exhaust gas in the outer cylinder, when the catalyst carrier is pressed into the outer cylinder along with the conveyor with respect to the supplied outer cylinder with the high friction portion in advance during the process of making a catalyst device, the catalyst carrier can be pressed inwardly from the end on the side opposite the high friction portion.

In this way, as long as the high friction portion does not obstruct the adjustment with pressure, the catalyst carrier can be easily pressed in, making manufacturing easier. 30 Also, the high friction portion can be formed by making the same catalyst as the catalyst carried by the catalyst carrier adhere to the inner face of the outer cylinder.

In this case, since the high friction portion is a portion whose surface roughness is rough because it has the same catalyst as that of the catafisador conveyor attached to the inner face of the outer cylinder, it can be easily formed. 5 Also, the high friction portion can be arranged at least in part of the portion in contact with the mat on the surface of the catalyst carrier.

In this case, provided that the high-friction portion with the highest

Friction efficiency is arranged at least in a part of the portion where the surface of the catalyst conveyor is in contact with the belt, the catalyst conveyor is fixed to the belt by friction with the high friction portion.

In this way, the catalyst carrier can be attached to the belt by friction between the catalyst carrier and the conveyor, and the catalyst carrier can be attached to the outer cylinder with a simple structure.

Also, the high friction portion can be formed by making the same catalyst as the catalyst transported within the catalyst carrier adhere to the surface of the catalyst carrier.

In this case, since the high friction portion is a portion whose surface roughness is rough because it has the same catalyst as the catalyst carrier adhered to the surface of the catalyst carrier, it can be easily formed.

Also, the catalyst carrier can be formed by ceramic. In that case, the catalyst carrier can be easily manufactured by forming the catalyst carrier by ceramic.

Furthermore, it can be configured in such a way that the surface roughness on the surface of the catalyst conveyor becomes rough before sintering the ceramic and then the catalyst conveyor is sintered and in this case, the roughness of The surface on the surface of the catalyst carrier can be rough and a high friction portion can be easily arranged.

Also, the high friction portion can be formed by having the catalyst also adhered to the surface of the catalyst carrier in a process in which the catalyst is created to be transported within the catalyst carrier. 5 In this case, in the process in which the catalyst is transported inside the catalyst carrier, since the high friction portion can be formed by having the catalyst adhered to the catalyst carrier surface at the same time, a process just to arrange

"the high friction portion is not necessary, and the high friction portion can be easily formed. ~ Also, in the above configuration, at least in part of the inner face of the outer cylinder, a predetermined material that can be oxidized more easily. than a stainless material in the exhaust gas of the internal combustion engine can be disposed.15 In that case, provided that the predetermined material that can be oxidized more easily than the stainless material is disposed on the inner face of the outer cylinder, the predetermined material is oxidized using the catalyst device and the surface roughness on the surface of the predetermined material becomes rough.

In this way, as long as the friction coefficient of the surface of the predetermined material is increased, the catalyst conveyor and conveyor can be fixed in a predetermined position by the friction between the predetermined material and the conveyor.

Also, since the predetermined material does not have a high surface roughness in the state before use in which oxidation has not yet progressed, a smooth pressure adjustment can be carried out in the compression process on the catalyst carrier with the conveyor belt. inside the outer cylinder.

Then, after the start of the use of the catalyst device, when the predetermined material disposed in the external cylinder is exposed to the exhaust gas and rapidly oxidized by the influence of the oxidizing gas in the exhaust gas 30 and / or a high temperature of the exhaust gas. discharge and surface roughness becomes rough.

Therefore, the catalyst conveyor and conveyor can be fixed quickly after starting use.

As mentioned above, according to the configuration of the present invention, the belt and conveyor

, of the catalyst can be fixed with a simple configuration.

Here, the predetermined material that can be oxidized more easily than the oxidizable material is a material in which the oxidation reaction progresses under the condition that a film in the passive state of the stainless material is not oxidized / deteriorated, for example. This is, a material oxidized at a temperature lower than the temperature at which the passive film of the stainless material is oxidized / deteriorated or the

"material in which oxidation progresses under an atmosphere of oxidizing gas in which the film in the passive state of the stainless material can be kept stable and which is specifically an iron or similar material.

Also, the stainless material here is SUS430 or similar.

Also, the predetermined material is exposed to at least part of the inner face of the outer cylinder and the entire outer cylinder can be formed by the predetermined material or only a part can be formed by the predetermined material so as to be exposed to the inner face of the cylinder external.

In the above configuration, the predetermined material can be a material in which the oxidation progresses at a temperature less than the temperature at which the stainless material is oxidized in the exhaust gas of the internal combustion engine.

In this case, in the discharge gas, by using a material in which the oxidation progresses at a lower temperature according to the predetermined material, if the material is exposed to the discharge gas, it is quickly oxidized and its surface roughness it gets rough and so, even in an environment where the exhaust gas cannot be increased easily, the catalyst conveyor and conveyor can be fixed quickly after the material is exposed to the exhaust gas.

Also, in the above configuration, the predetermined material can be formed by SP material (general carbon steel). In this case, through the use of carbon steel, which is inexpensive and excellent in machinability, a configuration that can easily fix the conveyor.

catalyst carrier and the conveyor can be easily made.

Also, in the above configuration, in the predetermined material, an additive material of the same composition as the material that forms the mat or a composition that contains a common element with material 5 can be added, and the predetermined material can be arranged in a position in contact with the mat on the inner face of the outer cylinder.

In this case, an additive material of the same composition as the material that forms the mat or a composition containing an element

"Common with the material is added to the predetermined material arranged on the inner face of the outer cylinder, and the predetermined material is in contact ~ with the mat.

Therefore, since the affinity between the inner face of the outer cylinder and the mat in contact with each other is extremely tight, the mat and inner face of the outer cylinder can be made to adhere to each other favorably, and the mat and the the catalyst carrier can be fixed.

Also, the present invention provides a method of manufacturing a catalyst device, which includes a first process of forming a mounting unit consisting of a ceramic catalyst carrier that carries a catalyst having a discharge purification function. and a mat wrapped around the outer side of the catalyst carrier that are contained in the outer cylinder, a second process of inducing a catalyst having the function of discharge purification to adhere to the interior of the catalyst carrier contained in the assembly unit and a region that includes at least one of a portion in contact with a portion of the belt end on the inner face of the outer cylinder or its proximity and a third sintering process of the assembly unit in which the catalyst is adhered to.

According to this manufacturing method, after the assembly unit is formed in the first process, the catalyst is induced to adhere inside the catalyst carrier in the second process and at the same time, the catalyst can be induced to adhere on the inner face of the outer cylinder and thus a process only to induce the

Straightener to adhere to the inner face of the outer cylinder is not necessary.

In addition to

. moreover, by sintering in the third process, the catalyst can be firmly adhered to and at the same time, the mat can be secured by heating the inner face of the outer cylinder in order to fix the mat to the outer cylinder 5.

In this way, a process just to secure the belt by heating is not necessary.

Therefore, the manufacturing efficiency is good and the catalyst device can be easily manufactured.

Also, since the catalyst carrier and the belt can be contained in the outer cylinder before the catalyst adheres to the inner face of the outer cylinder, the mounting unit can be easily formed.

For example, if the catalyst carrier and the conveyor must be contained in the outer cylinder by the pressure adjustment, since the catalyst does not adhere to the inner face of the external cylinder, the frictional resistance during the pressure adjustment is small, and pressure adjustment can be easily performed.

Also, the present invention provides a structure for retaining a catalyst carrier characterized in that a catalyst carrier having a cylindrical shape and retaining a catalyst having the function of purifying the discharge in a porous structure inside it is contained in an outer cylinder, a belt is compressed between the catalyst carrier and the outer cylinder and a high friction portion is arranged at least in part of the portion in contact with the belt on the surface of the catalyst carrier .

Here, the cylindrical shape refers to a hollow shape with an arbitrary sectional shape, not limited to a cylinder with a circular cut.

According to this configuration, since the high friction portion with the highest friction coefficient is arranged at least in a part of a portion where the surface of the catalyst conveyor is in contact with the conveyor, the catalyst conveyor is fixed on the conveyor at 30 friction with the high friction portion.

In this way, the catalyst carrier can be attached to the belt by friction between the catalyst carrier and the conveyor and the catalyst carrier can be attached to the outer cylinder with a simple structure.

Advantageous effects of the invention With the catalyst device according to the present invention, provided that the catalyst carrier can be attached to the outer cylinder 5 by friction at least between the catalyst carrier and the belt or by friction between the belt and the outer cylinder, the catalyst carrier can be fixed to the outer cylinder with a simpies frame.

Also, since the catalyst carrier can be secured

- attached to the outer cylinder by the friction between the belt and the outer cylinder, the catalyst carrier can be fixed to the outer cylinder with a simple structure.

Also, since the end portion of the mat is in contact with the high friction portion on the inner face of the outer cylinder or the mat and the high friction portion are brought into contact with each other if the mat is to be displaced by pressure of the discharge gas, the catalyst carrier can be attached to the outer cylinder by the friction between the belt and the outer cylinder.

Therefore, the catalyst carrier can be fixed to the outer cylinder with a simple structure.

Also, if the conveyor must be moved to the downstream side of the discharge, since the conveyor is attached to the outer cylinder by friction with the high friction portion disposed on the downstream side of the discharge, the catalyst carrier can be attached to the outer cylinder by the friction between the belt and the outer cylinder and the catalyst carrier can be fixed to the outer cylinder with a simple structure.

Furthermore, since the high friction portion is a portion 25 where the surface roughness becomes rough making the same catalyst as the catalyst carrier adheres to the inner face of the outer cylinder, it can be easily formed.

In addition, since the catalyst carrier can be attached to the outer cylinder by friction between the catalyst carrier and the belt, the catalyst carrier can be attached to the outer cylinder with a simple structure.

Also, since the high friction portion is a portion where the surface roughness becomes rough making the same catalyst that the catalyst carrier adheres to the surface of the catalyst carrier, it can be formed easily.

Also, since the catalyst carrier is formed of ceramic, the catalyst carrier can easily be manufactured light.

Furthermore, since the predetermined material disposed on the inner face of the outer cylinder is oxidized using the catalytic converter

"surface pain and roughness on its surface becomes rough, the mat and the catalyst carrier can be fixed in a predetermined position by the friction between the predetermined material and the mat.

Also, since the predetermined material does not have great surface roughness in the state in which oxidation has not progressed before use, in the process of compressing the catalyst carrier with the mat into the outer cylinder, they can be pressed to inside smoothly.

Therefore, the catalyst belt and conveyor can be securely fixed in a predetermined position with a simple configuration.

Also, even in an environment where the temperature of the exhaust gas cannot be easily raised, the catalyst conveyor and conveyor can be fixed quickly after they are exposed to the exhaust gas.

In addition, due to the use of carbon steel, which is inexpensive and excellent in machinability, the configuration to fix the catalyst conveyor and the belt can be easily carried out with simple configuration. 25 Furthermore, since the additive material of the same composition as the material that constitutes the mat or of a composition containing a common element with the material is added to the predetermined material disposed on the inner face of the outer cylinder, the affinity between the inner face of the outer cylinder and the mat in contact with each other is extremely high and the mat can be favorably induced to adhere to the inner face of the outer cylinder and the mat and catalyst carrier can be fixed firmly in a predetermined position.

Also, since the catalyst is induced to adhere to the

, surface of the catalyst conveyor at the same time as adhesion inside the catalyst conveyor, a process only to dispose

"a high friction portion is not necessary and the high friction portion can be formed easily.

Furthermore, since a process just to make the catalyst adhere to the inner face of the outer cylinder and a process only to secure the mat by heating are not necessary, the manufacturing efficiency is good and the catalyst device can be easily manufactured . 10 Furthermore, since the catalyst carrier and the conveyor can be contained in the outer cylinder before the catalyst is induced to adhere to the inner face of the outer cylinder, the assembly unit can be easily formed.

Brief description of the drawings 15 Figure 1 is a schematic diagram showing an exhaust silencer supplied with a catalytic converter according to a first embodiment.

Figure 2 is an exploded perspective diagram illustrating a configuration of the catalyst device. Figure 3 is a sectional view of the catalyst device.

Figure 4 is a schematic diagram showing an exhaust muffler provided with a catalyst device according to a second embodiment.

Figure 5 is an exploded perspective diagram illustrating a configuration of the catalyst device.

Figure 6 is a sectional view of the catalyst device.

Figure 7 is a schematic diagram showing an exhaust muffler provided with a catalyst device according to a third embodiment. Figure 8 is an exploded perspective diagram illustrating a configuration of the catalyst device.

Figure 9 is a sectional view of the catalyst device.

Figure 10 is a schematic diagram that illustrates a method

, manufacturing the catalyst device.

Figure 11 is a schematic diagram illustrating a method that induces a catalyst to adhere to a catalyst carrier. 5 Figure 12 is a schematic diagram illustrating a method that induces a catalyst to adhere to a catalyst carrier.

Figure 13 is a schematic diagram illustrating a discharge silencer provided with a catalyst device according to a seventh modality. Figure 14 is an exploded perspective diagram illustrating a configuration of the catalyst device.

Figure 15 is a sectional view of the catalyst device.

Figure 16 is a graph that illustrates the high temperature resistance of the external cylinder of the catalytic device. 15 Figure 17 is a schematic diagram showing an exhaust silencer supplied with a catalyst device according to an eighth mode.

Figure 18 is a sectional view of the catalyst device.

Figure 19 is a sectional view illustrating a structure of the discharge pipe provided with a catalyst device according to a ninth embodiment.

Figure 20 is a sectional view illustrating a structure of the exhaust pipe provided with a catalytic device according to a tenth embodiment. 25 Figure 21 is an enlarged diagram that illustrates a configuration of the joined portion in the tenth modality.

Figure 22 is a sectional view of a discharge silencer provided with a ceramic catalyst device according to an eleventh embodiment. 30 Figure 23 is a sectional view of the exhaust muffler seen from a different direction from that in Figure 22. Figure 24 is a diagram offered to explain the layout of the catalytic converter and a portion of the exhaust pipe end.

. ga.

Figures 25 are explanatory diagrams of a variation in the

"eleventh embodiment, in which figure 25A is a side sectional view illustrating a catalyst device according to a variation along with the peripheral configuration and figure 25B is a sectional view of the catalyst device in figure 25A.

List of reference signals 1, 4, 7, 8, 9, 50, 150 catalyst device 10 5 fine pore 10, 40, 60 catalyst carrier 12, 42, 62 holding mat 13, 43, 63, 73, 83, 84, 421 outer cylinder 14, 64, 74, 114 high friction portion 15 90, 92 discharge pipe made of titanium 91 conical portion 93, 95 discharge pipe made of stainless 94, 96 connection piece 75, 100, 106, 200, 300, 400 discharge silencer 20 110, 410 discharge pipe 120, 420 cylindrical main body 121 front end portion 122 rear end portion 140, 141 structure of the discharge pipe 25 Description of modalities Modalities in which the present invention is applied will be described below with reference to the attached drawings.

First embodiment Figure 1 is a diagram that schematically illustrates a discharge silencer 100 provided with a catalyst device 1 in accordance with a first embodiment of the present invention.

The exhaust muffler 100 is arranged on a motorcycle, connected at one end

rear exhaust pipe 110 extended from a motorcycle engine (not shown) and functions as a silencer that decompresses the exhaust gas at high temperature / high pressure having passed through the exhaust pipe 110 and discharges it to the outside . 5 The exhaust muffler 100 has a cylindrical main body 120 to which the single extended exhaust pipe 110 of the engine is connected, and the catalyst device 1 provided with a catalyst carrier 10 made of ceramic is supported on the cylindrical main body 120. The Catalyst device 1 includes the catalyst carrier 10 that carries a catalyst, an outer cylinder 13 that contains the catalyst carrier 10 and a holding mat 12 disposed between the catalyst carrier 10 and the outer cylinder 13. And the catalyst device 1 includes the catalyst carrier 10 around which the holding mat 12 is wrapped contained in the outer cylinder 13. The main cylindrical body 120 has an internal space of the same divided into a pIurality of (three in this example) expansion chambers A, B and C by a plurality of (two pieces in this example) bulkheads 131 and 132, in which an end portion 11OA of the discharge pipe 110 penetrates a front end portion 121 of the cylindrical main body 120 and is attached to the expansion chamber B, and the catalytic device 1 penetrates and is attached to the first bulkhead 131 closest to the end portion 11OA of the discharge pipe 110 The catalyst device 1 causes the end portion 11OA of the discharge pipe 110 to communicate with the expansion chamber A through a large number of fine pores 5 formed in the catalyst carrier 10 and the discharge gas discharged from the discharge portion. end 11OA is purified when passing through the catalyst carrier

10. Here, the outside diameter of the catalytic device 1 is formed wider than the outside diameter of the exhaust pipe 110, and a substantially ring-shaped positioning element 105 for positioning the end portion 11OA substantially coaxial with the catalyst conveyor 10 is interposed on an inner face of the outer cylinder 13A,

which is an inner face of outer cylinder 13, and an outer face of end portion 11OA.

Also, in the first bulkhead 131, a first communication pipe 135 and a second communication pipe 136 penetrate and are fixed in displaced positions of the catalyst device 1, in which the first communication pipe 135 forms the expansion chamber. A and the expansion chamber B communicate, while the second communication pipe 136 crosses the expansion chamber A and penetrates the second bulkhead 132, in order to make the expansion chamber B and the expansion chamber C communicate. l nicar.

In a rear end portion 122 of the cylindrical main body 120, a barrel element 138 constitutes a penetrating rear barrel and is fixed, while the barrel element 138 forms the expansion chamber C and the space outside the muffler discharge 110 communicate.

In the exhaust muffler 100, the exhaust gas discharged from the end portion 11OA of the exhaust pipe 110 passes through the catalytic device 1 and flows into the expansion chamber A in the exhaust silencer 100 as shown by the arrow in figure 1 , reverses the flow direction and passes through the first communication pipe 135 and flows into the expansion chamber B, reverses the flow direction again and passes through the second communication pipe 136 and flows into the expansion chamber C and it is discharged to the outside through the pipe element 138 that constitutes the rear pipe.

Since the sectional area of the main cylindrical body 120 is formed wider than the discharge pipe 110 inserted in the main cylindrical body 120, the discharge gas is decompressed when it flows into each of the expansion chambers A to C .

Also, since the catalyst device 1 is disposed in the cylindrical main body 120 of the exhaust silencer 100, the space of the Ieeute for the catalyst device 1 is easily guaranteed.

Also, since the catalyst device 1 is arranged substantially coaxial with the end portion 11OA of the discharge pipe 110, the exhaust gas discharged from the end portion 11OA of the discharge pipe 110 can be induced to flow inward. catalyst device 1 without changing its flow direction.

Figure 2 is an exploded perspective view illustrating the configuration of the catalyst device 1. The catalyst carrier 10 is a body of porous structure with an alveolar state formed in a cylindrical shape and having a large number of fine pores 5 extended along the axial direction within an outer casing of the cylindrical shape and the area of the inner surface is formed large.

Here, the sectional shape of the catalyst carrier 10 is arbitrary and the sectional shape is not limited to circular, but can be an oval, for example.

On the wall of each fine pore 5, platinum, rhodium and palladium that make up the exhaust gas component are transported as a catalyst.

As the base material of the catalyst carrier 10, a porous ceramic is used and a catalyst such as patin, rhodium, palladium and so on can be easily transported.

Here, as a preferable example of a ceramic material, various heat-resistant ceramics including cordierite, mullite, alumina and alkaline earth metal aluminate, silicon carbide, silicon nitride or the like or their similar substances can be used.

Also, an external circumferential face of the catalyst carrier 10 is formed with greater surface roughness and friction coefficient.

The retention mat 12 is formed by the compression or integration of ceramic fibers in a long mat state, and is wrapped around the outer circumferential face of the catalyst conveyor 10. At one end of the retention mat 12, a portion of projection-shaped joint 12J is formed, while at the other end, a recessed-shaped joint portion 12K is formed and in this way, when the holding mat 12 is wrapped around the catalyst carrier 10, the two portions coupling 12J and 12K come together and they are securely engaged.

Also, since the holding mat 12 is a collection in which the fibers intertwine, it has a relatively high elasticity.

Here, the material of the holding mat 12 can be anything as long as it has heat resistance and elasticity, and the integration of fibrous metals or glass wool or the like can also be used.

Since "the retaining mat 12 has elasticity, it can protect the catalyst carrier 5 made of ceramic against vibration or impact.

Furthermore, the retaining mat 12 is a collection in which the fibers intertwine and numerous fine voids are formed on the surface and inside.

Thus, the surface of the holding mat 12 is in a state in which numerous thin projections and recesses are formed, and since the surface roughness is high, the friction coefficient on the surface is high.

Therefore, since the friction is high on the contact face between the catalyst carrier 10 and the holding mat 12, the catalyst carrier 10 is attached to the holding mat 12. As the material of the outer cylinder 13, a metal with high resistance and heat resistance is used and a steel material such as stainless can be used, for example.

Containment methods of the catalyst carrier 10 around which the holding mat 12 is wound on the outer cylinder 13 includes adjustment with pressure, potting, winding and tightening and so on.

In order to press the catalyst carrier 10 into the outer cylinder 13, the catalyst carrier 10 around which the holding mat 12 is wound is pushed into the outer cylinder 13 formed in advance by the cylinder. 25 In order to contain the catalyst conveyor 10 by filling, the catalyst conveyor 10 around which the holding mat 12 is wound is surrounded by divided parts formed so as to divide a cylinder into a plurality of parts to the axle in the axial direction, and the split parts are joined to form the outer cylinder 13. 30 Also, in order to contain the catalyst carrier 10 by winding and tightening, a sheet material is wrapped around the catalyst carrier 10 around which the holding mat 12 is wound and the end portions of the sheet material are joined together

_ how to form the outer cylinder 13. Here, the union of potting and winding and tightening is carried out by welding, adhering, screwing or the like.

Also, the holding mat 12 is compressed between the outer cylinder 13 and the catalyst carrier 10 and contained in a compressed state, not using pressure, filling, winding and tightening methods or the like.

Figure 3 is a sectional view of the catalyst device 1. In the catalyst device 1, the exhaust gas flows in the direction 10 shown by arrow D in figure 3. The catalyst device 1 consists of an assembly unit 15 consisting of containing the conveyor of the catalyst 10 and the holding mat 12 in the outer cylinder 13. Here, the lengths in the axial direction of the outer cylinder 13 and the catalyst carrier 10 are 15 substantially the same, while the length of the holding mat 12 in the axial direction is shorter than the lengths of outer cylinder 13 and catalyst carrier 10. Then, the mounting unit 15 is mounted in the state where the positions of both ends of outer cylinder 13 and both 20 ends of the catalyst carrier 10 substantially match.

On the other hand, the holding mat 12 is mounted so that the portion of the upstream end 12C of the holding mat 12 located on the upstream side of the discharge and the portion of the downstream end 12D of the holding mat 12 located on the downstream side are located inside the outer cylinder 13 than both ends of the outer cylinder 13. Therefore, one end of the outer cylinder 13 located on the downstream side with respect to the discharge flow constitutes an extended portion 16 formed of so as to extend farther than the portion of the downstream end 12D of the holding mat 12. Also, the other end of the outer cylinder 13 is extended so that the other end of the outer cylinder 13 is extended from the end portion upstream 12C.

In the catalyst device 1, a high friction portion 14 with

the surface roughness and high friction coefficient is arranged on the face of an extended portion 16 in the vicinity of the downstream end portion 12D. The high friction portion 14 is formed by making the same catalyst as the catalyst transported inside the catalyst conveyor 5 10 adhere to the inner face of the outer cylinder 13A. The high friction portion 14 has high surface roughness and up to a coefficient of friction since the adherent catheter forms thin projections and recesses on its surface The retaining mat 12 wrapped around the catalyst carrier 10 and cylindrically contained in the outer cylinder 13 has an outer face 10A, which is an outer circumferential face of it, in contact with the inner face of the outer cylinder 13A, which is an inner circumferential face of the outer cylinder 13 and has an inner face 12B, which is an inner circumferential face of it, in contact with the outer circumferential face of the catalyst conveyor 10. 15 Since the holding belt 12 is in a compressed state, the force to compress the outer cylinder 13 from the side of the inner face of the cylinder external ndro 13A and the force to compress the catalyst carrier 10 are exerted by a compression reaction force. Then, the retaining belt 12 has the outer face 12A compressing the outer cylinder 20 13 from the side of the inner face of the outer cylinder 13A and is attached to the outer cylinder 13 by the friction generated between the outer face 12A and the inner face of outer cylinder 13A. Also, the holding mat 12 compresses the outer circumferential face of the catalyst conveyor 10 and fixes the catalyst conveyor 10 by the friction generated between the inner face 12B and the outer circumferential face of the catalyst conveyor 10. In the catalyst device 1, the exhaust gas having advanced into the outer cylinder 13 passes through each fine pore 5 of the catalyst carrier 10 and is purified and then exits the outer cylinder

13. Here, since the fibers are brought together in a high density on the retaining mat 12, the mat has the function as a sealing material for the exhaust gas in addition to the function as a carrier retaining element.

catalyst carrier 10 and therefore the exhaust gas cannot

, pass through the retaining belt 12. Therefore, since all the exhaust gas passes through the catalyst device 1, the efficiency of the purification

"tion is high. 5 In this first embodiment, as shown in figure 3, the high friction portion 14 is arranged in the extended portion 16 in the vicinity of the downstream end portion 12D on the inner face of the outer cylinder 13A.

As a result, if the holding mat 12 is to be moved to the downstream side of the discharge, the holding mat 12 can be attached to the inner face of the outer cylinder 13A by friction with the high friction portion 14.. If the exhaust gas flows through the discharge pipe 110, the holding mat 12 is subjected to the force to be displaced downstream of the discharge by the pressure of the discharge gas and so on.

However, even if the holding mat 12 in the compressed state within the catalyst device 1 is moved to the downstream side by a slight distance, the mat is captured by the high friction portion 14 formed on the inner face of the extended portion 16 in the vicinity of the downstream end portion 12D.

At that time, since a high friction can be obtained between the outer face 12A of the holding mat 12 in the vicinity of the portion of the downstream end 12D and the high friction portion 14, the holding mat 12 can be attached to the outer cylinder 13. In this way, the catalyst carrier 10 can be attached to the outer cylinder 13 by the friction between the retaining mat 12 and the outer cylinder 13. Also, in the first mode, provided that the retaining mat 12 and the catalyst carrier 10 can be easily attached to the outer cylinder 13 without using a barrier element or the like and the catalyst device 1 can be formed in a compact style, the catalyst device 1 can be easily installed in the exhaust silencer 100 or other portions in the exhaust pipe on a motorcycle that tends to have limited space, for example.

Furthermore, since the retaining belt 12 and the catalyst carrier 10 are attached to the outer cylinder 13 by increasing friction, increasing the surface roughness of the inner face of the outer cylinder 13A, there is no component exposed to the outside. Therefore, if the catalytic converter 1 is attached to a motorcycle, for example, it has the advantage that the appearance is not impaired. Also, as long as the barrier element or the like is not disposed in the discharge path 5 of the catalytic device 1, the flow of discharge is not obstructed by the element of the barrier or the like or the purification efficiency of the exhaust gas is not impaired . Also, since the friction coefficient of the high friction portion 14 is high, even though the compression reaction force generated when the holding mat 12 is compressed is not strictly controlled, sufficient friction can be obtained. In this way, since the tolerance for the resistance of the catalyst carrier 10, the density of the holding mat 12 and the inner diameter of the outer cylinder 13 and so on can be wider, the yield of each component is improved and the manufacturing cost can be reduced. As described above, according to the first embodiment in which the present invention is applied, provided that the high friction portion 14 that prevents movement between the holding mat 12 and the outer cylinder 13 is disposed between the catalyst carrier 10 and the outer cylinder 13, the catalyst carrier 10 can be attached to the outer cylinder 13 by friction with the high friction portion 14. In this way, the catalyst carrier 10 can be attached to the outer cylinder 13 with a simple structure . Also, on the inner face of the outer cylinder 13A, since the high friction portion 14 is disposed in the vicinity of the downstream end portion 12D of the retaining mat 12, the retaining mat 12 is fixed to the inner face of the outer cylinder 13A by friction with the high friction portion

14. In this way, the catalyst carrier 10 can be attached to the outer cylinder 13 by friction between the holding mat 12 and the outer cylinder 13 and the catalyst carrier 10 can be attached to the outer cylinder 13 with a simple structure. Also, if the holding mat 12 is to be moved to the downstream side of the discharge, the holding mat 12 is placed in contact with the high friction portion 14 arranged on the inner face of the extended portion.

of the 16 on the downstream side of the discharge and fixed by friction with the high

, friction 14. In this way, the catalyst carrier 10 can be attached to the outer cylinder 13 by friction between the holding mat 12 and the "outer cylinder 13 and the catalyst carrier 10 can be attached to the outer cylinder 5 with a frame simple.

Furthermore, since the high friction portion 14 is a portion with increased surface roughness by making the same catalyst as the catalyst carrier 10 adheres to the inner face of the outer cylinder 13A, it can be easily formed. 10 Also, since the catalyst carrier 10 is made of ceramic, the catalyst carrier 10 can be easily manufactured.

Second modality A second modality in which the present invention is applied will be described below with reference to figures 4 to 6. In this second modality, portions configured similarly to the first modality are indicated with the same reference numerals and description. will be omitted.

Figure 4 is a diagram showing schematically a discharge silencer 200 provided with a catalyst device 50 according to the second embodiment of the present invention.

In the second embodiment, instead of the catalyst conveyor 10 in the first embodiment, a catalyst conveyor 60 is disposed within the exhaust muffler 200. The second embodiment is different from the first embodiment in that a high friction portion 64 that secures the catalyst carrier 60 is formed on the surface of the catalyst carrier 60. As shown in figure 4, the exhaust muffler 200 has a cylindrical main body 120 in which the single exhaust pipe 110 extended from the engine is connected and the catalyst device 50 provided with the catalyst carrier 60 made of ceramic is supported on the main cylindrical body 120. The catalyst device 50 includes the catalyst carrier

talisator 60 that carries a catalyst, an outer cylinder 63 that con-

, has the catalyst carrier 60 and a retaining belt 62 disposed between the catalyst carrier 60 and the outer cylinder 63. And the catalyst device 50 includes the catalyst carrier 60 around which the retaining belt 62 is rolled up contained in the outer cylinder 63. Figure 5 is an exploded perspective view illustrating a configuration of the catalyst device 50. Figure 6 is a sectional view of the catalyst device 50. The catalyst carrier 60 is a porous structure body l The alveolar state shape formed in a cylindrical shape and having a large number of fine pores 5 extended along the axial direction within an outer casing of the cylindrical shape and an internal surface area is formed large.

Here, the sectional shape of the catalyst carrier 60 is arbitrary and the sectional shape is not limited to circular, but can be oval, for example.

In a wall of each fine pore 5, platinum, rhodium and palladium that break down the exhaust gas component are transported as catalysts.

Also, in the part of the outer surface 61, which is the surface of the outer circumference of the catalyst carrier 60, the high friction portion 64 in which the same catalyst as the catalyst adhering to the interior of the catalyst carrier catheter 60 adheres is formed.

The methods for containing the catalyst carrier 60 around which the retaining belt 62 is wound on the outer cylinder 63 include adjustment with pressure, potting, winding and tightening and so on, and with any of these methods, the holding mat 62 is compressed between the outer cylinder 63 and the conveyor of the catalyst 60 and is contained in the compressed state.

The lengths in the axial direction of the catalyst carrier 60 and the holding mat 62 are substantially the same and in the state in which the catalyst device 50 is mounted, both ends of the catalyst carrier 60 and the holding mat 62 are joined.

Also, the length of the outer cylinder 63 is longer than the lengths

catalyst conveyor 60 and retaining belt 62 e. both ends of the catalyst carrier 60 and the retaining mat 62 are located inside the outer cylinder 63. Since the retaining mat 62 is in the compressed state, 5 the force to compress the catalyst carrier 60 and the force to com- pressing the outer cylinder 63 from the inner circumferential side of the outer cylinder 63 are exerted by the compression reaction force. Then, the catalyst carrier 60 receives the compressive force through the holding mat 62 on the entire surface of the outer surface 61 and is fixed to the holding mat 62 by the friction generated between the catalyst carrier 60 and the holding mat 62. Also, the holding mat 62 exerts the compression force on the inner circumferential face of the outer cylinder 63 and is fixed on the outer cylinder 63 by the friction generated between the outer cylinder 63 and the holding mat 62. In the catalyst device 50, the discharge flows in a direction indicated by the arrow D in figure 6 and the exhaust gas having advanced into the outer cylinder 63 passes through each fine pore 5 of the catalyst carrier 60 and is purified and then exits the outer cylinder

63. Here, on the retention mat 62, since the fibers are brought together in high density in order to also function as a sealing material for the exhaust gas in addition to the function as a protective element of the catalyst carrier 60, the gas discharge cannot pass through the retention mat 62. Thus, since the discharge gas passes only through each fine pore 5, the purification efficiency is high. In the second embodiment, as shown in figures 5 and 6, the high friction portion 64 with the highest friction coefficient is at least part of the outer surface 61 of the catalyst carrier

60. In detail, the high friction portion 64 is formed into a portion of the upstream end 60A, which is an end on the upstream side of the discharge stream in the catalyst carrier 60. As a result, the catalyst carrier 60 can be fixed on the retaining belt 62 by friction with the high friction portion 64.

Within the catalyst device 50, the catalyst carrier

, pain 60 is subjected to the compression force by the holding mat 62 in the compressed state.

Then, the high friction portion 64 is formed on the catalyst carrier 60 and if it is subjected to the compressive force, great friction can be obtained between the high friction portion 64 with the high friction coefficient and the belt retainer 62. Also, since the high friction portion 64 is formed at the end on the upstream side in the discharge flow in the catalyst carrier 60, if the catalyst carrier 60 is to be moved to the downstream side, for example , the high attrition portion 64 is displaced while generating friction over the entire length of the retention mat 62. In this way, a high effect to prevent the displacement of the catalyst carrier 60 can be obtained.

As mentioned above, since the catalyst carrier 60 is attached to the holding mat 62 by the friction between the high friction portion 64 and the holding mat 62, the catalyst carrier is not displaced from the holding mat 62 even if it is subjected to pressure by the discharge gas from the discharge pipe 110. Here, the high friction portion 64 is formed on the strip where the friction that can safely secure the catalyst carrier 60 to the holding belt 62 can be obtained .

Also, in the second embodiment, since the catalyst carrier 60 can be easily attached to the retaining belt 62 without using an obstacle or the like and the catalyst device 50 can be constructed in a compact style, the catalyst device 50 can be easily installed. in the exhaust muffler 200 or other portions in the exhaust pipe on a motorcycle that tends to have limited space, for example.

Furthermore, since the catalyst carrier 60 is attached to the retaining mat 62 increasing friction and increasing the surface roughness of the catalyst carrier 60, there is no component exposed to the outside.

Therefore, if the catalyst device 50 is attached to a motorcycle, for example, this has the advantage that the appearance is not impaired.

Also, since a barrier element or the like is not disposed in the discharge path of the catalytic device 50, the discharge flow is not impeded

the barrier element or the like or the purification efficiency. of the exhaust gas is not deteriorated. Also, since the friction coefficient of the high friction portion 64 is high, even though the compression reaction force generated when the holding mat 62 is compressed 5 is not strictly controlled, sufficient friction can be obtained. Thus, since the dimensional tolerance for the strength of the components that make up the catalyst carrier 50 can be set higher, the yield of each component is improved and the manufacturing cost can be reduced. according to the second embodiment in which the present invention is applied, provided that the high friction portion 64 that prevents movement between the holding mat 62 and the outer cylinder 63 is disposed between the catalyst carrier 60 and the outer cylinder 63, the catalyst carrier 60 is attached to the outer cylinder 63 by friction 15 with the high friction portion 64. In this way, the catalyst carrier 60 can be attached to the outer cylinder 63 with a simple structure. Also, since the high friction portion 64 with high friction coefficient is formed on a part of the outer surface 61 of the catalyst carrier 60, the catalyst carrier 60 is attached to the outer cylinder 63 by friction between the portion high-friction 64 and the holding mat

62. In this way, the catalyst carrier 60 can be attached to the outer cylinder 63 by friction between the catalyst carrier 60 and the holding track 62, and the catalyst carrier 60 can be attached to the outer cylinder 63 with a simple structure. "Also, since the high friction portion 64 is a portion with greater surface roughness making the same catalyst as the catalyst carrier 60 adheres to the outer surface 61, it can be formed easily. In addition moreover, since only a quantity of the catalyst required for fixing the catalyst carrier 60 is used by making the catalyst adhere to a part of the outer surface 61, the catalyst can be saved. of the catalyst 60 is formed by ceramic, the catalyst carrier 60 can be easily manufactured lightly .. Third embodiment A third embodiment in which the present invention is applied will be described below c with reference to figures 7 to 9. In this third mode, portions configured similarly to the first mode are indicated with the same reference numerals and the description will be omitted.

Figure 7 is a diagram showing schematically a discharge silencer 300 with a catalyst device 150 according to the third embodiment of the present invention.

In the first embodiment, the high friction portion 14 is formed in the portion of the downstream end 12D of the inner face of the outer cylinder 13A, but the third embodiment is different from the first embodiment in which, in addition to the high friction portion 14, a portion high friction 114 is formed on the outer surface 11, which is an outer circumferential face of the catalyst carrier 10 of the first embodiment.

Figure 8 is an exploded perspective view illustrating a configuration of the catalyst device 150. Figure 9 is a sectional view of the catalyst device 150. In the catalyst device 150, the high friction portion 14 is formed at the end portion a downstream 12D from the inner face of the outer cylinder 13A.

Furthermore, in the catalyst device 150, in the vicinity of the upstream end portion 12C of the holding mat 12, the high friction portion 114 is formed in a portion where the holding mat 12 is in contact with the outer surface 11 of the catalyst carrier 10. And the high friction portion 114 and the high friction portion 14 are formed by making the same catalyst as the adherent catalyst inside the catalyst carrier 10 adheres.

As described above, according to the third embodiment in which the present invention is applied, provided that the high friction portion 14 is arranged in the vicinity of the downstream end portion 12D of the holding mat 12 on the inner face of the outer cylinder 13A, the retaining mat

, 12 is fixed on the inner face of the outer cylinder 13A by friction with the high friction portion 14. Furthermore, since the high friction portion 114 with the '' high friction coefficient is formed on a part of the outer surface 11 of the catalyst conveyor 10, the catalyst conveyor 10 is attached to the outer cylinder 13 by the friction between the high friction portion 14 and the holding mat 12. This is provided that the catalyst conveyor 10 is attached to the outer cylinder 13 friction between the outer cylinder 13 and the retaining belt

- tion 12 as well as the friction between the catalyst carrier 10 and the holding track 10, the catalyst carrier 10 can be fixed to the outer cylinder 13 with a simple structure.

Fourth embodiment An example of a method of manufacturing the catalyst device 1 shown in figure 3 will be described below. 15 Figure 10 is a diagram showing schematically one. method of manufacturing the catalyst device 1. In this method, a solution in which the catalyst is dissolved is provided from the underside of the catalyst device 1 in order to make the catalyst adhere to the catalyst device 1. 20 The catalyst device 1 is manufactured by the method manufacturing process that includes the following three processes.

A first process is a process of forming the assembly unit 15 containing the catalyst carrier 10 and the holding mat 12 on the outer cylinder 13. Specifically, first, the holding mat 12 is wound around the outer circumferential face of the transpor - cylindrical catalyst carrier 10. Then, the catalyst carrier 10 is pressed into the outer cylinder 13 together with the retaining belt 12 to form the mounting unit 15. A second process is a process of inducing the adhesion 30 of the catalyst inside the catalyst carrier 10 contained in the assembly unit 15 and a part of the inner face of the external cylinder 13A.

Specifically, first, as shown in figure 10, the mounting unit

15 is joined to a cylindrical body 500 and a catalyst solution

. adjusted to contain platinum, rhodium and palladium it is pressure fed as shown by arrow E through the cylindrical body 500 and adjusted "so that the catalyst solution reaches the upper end of the catalyst carrier 5 in figure 10. Then, the catalyst solution fits in each fine pore 5 inside the catalyst carrier 10 and in the vicinity of the downstream end portion 12D on the inner face of the outer cylinder 13A.

A third process is a sintering process of assembly unit 10 15. As a specific example, assembly unit 15 is removed from cylindrical body 500 and dried by hot air at 100 ° C for 10 minutes and then sintered at 450 ° C for 1 hour, for example.

As a result, the catalyst is transported on the inner face of the portion of the downstream end 12D and of the extended portion 16 and of the surface of each fine pore 5, 15 and the catalyst device 1 is completed.

Then, the high friction portion 14 formed causing the catalyst to adhere to the inner face of the extended portion 16 has high surface roughness and high friction coefficient since the adherent catalyst forms thin projections and recesses on its surface.

Also, by sintering at 450 ° C, since the retaining mat 12 is fixed on the inner face of the outer cylinder 13A, the effect to fix the retaining mat 12 on the outer cylinder 13 can be obtained.

Also, by the method of the fourth embodiment, the catalyst device 150 shown in figure 9 can also be manufactured.

In order to manufacture the catalyst device 150 shown in figure 9, as shown in figure 10, a plurality of hollow holes 11A are formed in the portion in the vicinity of the upstream end portion 12C on the outer surface 11 of the catalyst carrier 10. The holes Hollow holes 11A are holes that penetrate the interior of the catalyst carrier 10 and the pressure fed solution that passes through the interior of the catalyst carrier 10 exudes the hollowed holes 11A.

As a result, on the outer surface 11 of the catalyst carrier 10, the high friction portion 114 can be formed in the portion in the vicinity of the upstream end portion 12C shown in figure 9 making the solution a-

Pour it. Also, since the drilled holes 11A can be arranged in desired positions, the high friction portion 114 can be formed in "desired positions. 5 The catalyst solution for making the catalyst carrier 10 transport palladium, rhodium and platinum is made by dissolving a compound containing these metals in a predetermined solvent The materials used to make the transported palladium include nitrate salt, chloride, acetate salt, complex salt (palladium dichlorotetraamine or the like) and so on. , the materials used to make the transported pylatin include nitrate salt, chloride, acetate salt, complex salt (platinum dinitrodiamine, platinum trichlorotriamine or the like) or the like. Materials for making the rhodium carried by the catalyst carrier 10 include salt of nitrate, chloride, acetate salt, sulfate, complex salt (penaminachlororodine, hexaaminarodine or similar) or the like. of these materials and by impregnating the catalyst carrier 10 described above with this solution, the catalyst carrier 10 can be created to transport palladium, platinum and rhodium. As the solvent, water or organic solvents can be used, but water is preferable in view of the solubility, ease of treatment of the residual solution, availability and so on. Also, after the catalyst carrier 10 is impregnated with the solution, by heating and drying the catalyst carrier 10 to approximately 250 ° C, for example, palladium, rhodium and platinum are transported by the porous structure of the catalyst carrier. 10 and nitrogen oxides, HC (hydrocarbon), CO (carbon monoxide) and so on in the exhaust gas can be decomposed and purified. Depending on the required purification performance of the exhaust gas, the catalyst can be constituted by making only one or two types of palladium, rhodium and pIatin transported by the catalyst transporter 10. Alternatively, others besides palladium, rhodium and platinum, a metal or metal compound and so on functioning as a catalyst (iridium, cerium, zirconium, titanium or its oxides)

and so on) can be transported by the carrier of the

P lyser 10. As described above, according to the fourth embodiment in which "the present invention is applied, after the assembly unit 15 5 is formed in the first process, since the catalyst can be induced to adhere to the inner face of the outer cylinder 13A at the same time as the catalyst adheres to the catalyst carrier 10 in the second process, a process only to make the catalyst adhere to the inner face of the outer cylinder 13A is not necessary, and the manufacturing efficiency is good and catalyst positive device 1 can be easily manufactured, furthermore, by synthesizing it in the third process, the catalyst can be induced to adhere firmly and at the same time, the retaining mat 12 can be attached to the face inner cylinder 13A by heating so that the retaining mat 12 can be attached to the outer cylinder 13. Thus, a process only for securing the retaining mat 12 by heating is not necessary and the manufacturing efficiency is good and the catalytic converter 1 can be easily manufactured. Also, since the catalyst carrier 10 and the holding mat 12 can be pressed into the outer cylinder 13 in a state where the catalyst does not stick to the inner face of the outer cylinder 13A in the first process, the resistance of the friction in pressure adjustment is small, and pressure adjustment can be performed easily. Fifth embodiment An example of a method of manufacturing the catalyst carrier 60 shown in figure 6 will be described below. Figure 11 is a diagram that schematically illustrates a method of inducing catalyst adhesion to the catalyst carrier 60. In that method, a catalyst solution is provided from above the catalyst carrier 60 so that the catalyst is inert. - caused to adhere to the catalyst carrier 60. First, the catalyst carrier 60 is arranged so that the upstream end portion 60A is directed downwards, and

, a loading funnel 600 is arranged so as to be in contact with the upper end of the catalyst carrier 60 in figure 11. For the loading funnel

- charge 600, the catalyst solution is supplied and the solution of catalyst 5 flowing through the catalyst carrier 60 through the loading funnel 600 flows through the interior of the catalyst carrier 60 as shown by arrow F and the catalyst solution adheres to each fine pore 5 within the catalyst carrier 60. Then, on the outer surface 61 of the catalyst carrier 10 60, in the vicinity of the upstream end portion 60A, a plurality of hollow holes 61A is formed.

Hollow holes 61A are holes that communicate with the interior of the catalyst carrier 60 and the catalyst solution flowing into the catalyst carrier 60 exudes from the hollow holes 61A.

As a result, on the outer surface 61 of the catalyst carrier 15, the high friction portion 14 can be formed by making the catalyst solution adhere to a portion in the vicinity of the upstream end portion 60A.

As mentioned above, by forming the hollow holes 61A in the outer surface 61 of the catalyst carrier 60, the high friction portion 14 can be easily formed in a desired position.

As described above, according to the fifth embodiment in which the present invention is applied, provided that the high friction portion 64 is formed by making the catalyst adhere to the outer surface 61 at the same time in the process in which the catalyst is made to be transported within 25 of the catalyst carrier 60, the high friction portion 64 can be easily formed.

Sixth embodiment Another example of a method of manufacturing the catalyst carrier 60 shown in figure 6 will be described below. 30 Figure 12 is a diagram that schematically illustrates a method of inducing the adhesion of the catalyst on the catalyst carrier 60.

In this method, the catalyst solution is supplied from above the

, catalyst conveyor 60, so that the catalyst is induced to stick to the catalyst conveyor 60. In the catalyst conveyor 60, at the upper end in figure 12, the loading funnel 600 is arranged with a space provided.

For the funnel 600, the catalyst solution is provided and the catalyst solution flowing downward from the funnel 600 flows as shown by the arrow G inside the catalyst carrier 60 and also flows to the outer surface 61 from the upper face of the catalyst carrier 60 and flows downwardly along the outer surface 61. In this way, the catalyst solution adheres to most of each fine pore 5 within the catalyst carrier 60 of the outer surface 61, and therefore - high friction 64 can be easily formed over most of the outer surface 61. 15 Each of the above described modalities shows an aspect in which the present invention is applied and the present invention is not limited to the above modalities.

For example, in the first embodiment, the high friction portion 14 is explained as being arranged on the inner face of the extended portion 16 20 in the vicinity of the downstream end portion 12D, but the present invention is not limited to that and the high portion friction 14 can be arranged in a region that includes at least any one portion in contact with the portion of the downstream end 12D or its proximity.

For example, the high friction portion 14 can be formed on a contact face between the outer face 12A of the holding mat 12 and the inner face of the outer cylinder 13A.

In addition, the high friction portion 14 can be arranged on the inner face of outer cylinder 13A closer to the side upstream of the discharge than the upstream end portion 12C.

In that case, the displacement of the holding belt 12 to the side upstream of the discharge can be prevented.

Similarly, in the second embodiment, the high friction portion 64 is explained as being arranged in the upstream end portion

60A on the outer surface 61 of the catalyst carrier 60, but it is only necessary that the high friction portion 64 be arranged at least on part of the outer surface 61 or the high friction portion 64 can be arranged over the entire surface of the outer surface 61. Also, the portion where the high friction portion 64 is arranged is not limited to the upstream end portion 60A and the high friction portion 64 can be arranged centrally on the outer surface 61, for example.

In addition, in the second embodiment, the high friction portion 64 on the outer surface 61 is explained as being formed by making the catalyst adhere, but the high friction portion 64 can be formed by forming a face with high surface roughness such as type finish. pear peel or the like on the outer surface 61 of the catalyst carrier 60 for which work before sintering is easy when the ceramic catalyst carrier 60 is sintered and then, by sintering the catalyst carrier 60, for example.

Alternatively, the surface roughness of the outer surface 61 can be roughened by mechanical work or the like.

Also, in the third embodiment, the high friction portion 114 is explained as being formed in a portion where the holding mat 12 and the outer surface 11 of the catalyst carrier 10 are in contact in the vicinity of the upstream end portion 12C of the stay - retention frame 12, but the present invention is not limited to that.

For example, the high friction portion can also be arranged in a portion where the catalyst carrier 10 is not in contact with the holding mat 12 in the vicinity of the upstream end portion 12C.

It goes without saying that other detailed settings can be changed arbitrarily.

Also, in the fourth embodiment, the high friction portion 14 is explained as being formed after the assembly unit 15 is formed, but it can also be so configured that the high friction portion 14 is formed in advance in the inner face of the outer cylinder 13A and then the catalyst carrier 10 and the holding mat 12 are contained in the outer cylinder 13 by potting, winding and tightening or the like.

Also, it can be so configured that the high friction portion 14 is formed in advance on the inner face of the extended portion 16 on the inner face of the outer cylinder 13A and then, the catalyst carrier 10 and the holding mat 12 are pressed in 5 of the outer cylinder 13. In this case, the holding mat 12 and the catalyst carrier 10 can be easily pressed in from the end of the outer cylinder 13 on the side opposite the high friction portion 14 It goes without saying that other detailed settings can be changed arbitrarily.

Also, in the fourth mode, it is explained that the cylindrical body 500 is connected to the assembly unit 15 and the catalyst solution is fed with pressure from below, but it can also be so configured that the lower end of the assembly unit 15 is impregnated with the catalyst solution, for example, and the catalyst solution is pumped upwards from the upper end in order to make the catalyst solution adhere.

Also, in the first embodiment, the high friction portion 14 of the outer cylinder 13 is explained as being formed by making the catalyst adhere, but the high friction portion 14 can also be formed by making another substance that increases the friction to adhere and the ceramic. porous material can be struck, for example.

Also, the high friction portion 14 can be formed by making the surface roughened by mechanical or similar work.

Also, the catalyst carrier 10 of the first mode and the catalyst carrier 60 of the second mode are explained as being made of ceramic, but it can be so configured that the catalyst carrier 10 is formed by a metal, for example, and a porous ceramic layer with high surface roughness is formed on a part of the outer surface 61 of the metal catalyst carrier 10 and each fine pore 5 by sintering or the like and a catalyst is carried by this ceramic layer.

In this case, since the surface roughness of the outer surface 61 is roughened only by the formation of the ceramic layer, the function as the high friction portion

64 can be provided for that ceramic layer.

Also, preferable examples of the material for catalyst carriers 10 and 60 if catalyst carriers 10 and 60 are formed of metal include stainless steel, ferro-aluminum-chromium alloy or the like. Furthermore, the fifth embodiment shows an aspect in which the present invention is applied and the present invention is not limited to the fifth embodiment.

For example, in the fifth embodiment, the catalyst solution is explained to be induced to flow into the catalyst carrier 60 from the loading funnel 600, but the present invention is not limited to this, and it can be so configured that the end on the side of the upstream end portion 60A of the catalyst carrier 60 is impregnated with the solution of the catalyst and the catalyst solution is pumped up from the end on the side opposite to the end portion upstream 60A in order to make the catalyst solution adhere.

In this case, hollow holes 61A do not need to be provided.

Unlike the above, it goes without saying that the specific configuration in each of the first to sixth modalities can be changed arbitrarily.

Seventh embodiment Figure 13 is a diagram that schematically illustrates a discharge silencer 75 provided with a catalyst device 7 according to a seventh embodiment in which the present invention is applied.

The exhaust muffler 75 is arranged, similarly to the exhaust muffler 100 shown in figure 1, on a motorcycle and acts as a silencer that decompresses the exhaust gas at high temperature / high pressure having passed through the pipe discharge 110 and discharges it outside.

The exhaust muffler 75 has a cylindrical main body 120 to which the exhaust pipe 110 is connected and the catalytic device 7 supplied with the catalyst carrier 10 is supported on the main cylindrical body 120. The catalyst device 7 has an external cylinder 73 instead of the external cylinder 13 of the catalyst device 1 (figure 1) and the other components are common with those of the catalyst device 1. The catalyst device 7 penetrates and is attached to the first shield 131 closest to the end portion 11OA of the exhaust pipe 110, similarly to catalytic converter 1. Also, exhaust silencer 75 is constituted similarly to exhaust silencer 100, except at the point where catalyst device 7 is supplied instead of catalyst device 1. In this seventh modality, portions configured similarly to the first to sixth modalities are indicated with the same reference numbers and the description will be omitted.

Figure 14 is an exploded perspective view illustrating a configuration of the catalyst device 7. The catalyst carrier 10 is a porous structural body in an alveolar state formed cylindrically as mentioned above and a high friction portion 74 is formed on the outer surface 11. Also, like the material that constitutes the outer cylinder 73, a metal with high resistance and high heat resistance is used and particularly a metal material that can be oxidized relatively easily such as general carbon steel (so-called material SP) is used, for example.

Particularly, for the outer cylinder material 73, a material that is oxidized more easily than stainless material such as SUS 430 is preferable and more specifically, a material in which an oxidation reaction progresses under the condition in which a film in the passive state of the stainless material is not oxidized / deteriorated is preferable. This is, a material oxidized at a temperature lower than the temperature at which the passive film of the stainless material is oxidized / deteriorated or a material in which the oxidation progresses under a temperature of the oxidizing gas at which the film in the passive state the stainless material can withstand is preferable !. Figure 15 is a sectional view of the catalyst device 7. As shown in figure 15, the catalyst device 7 is constituted such that the outer surface 11 is held by the outer cylinder 73 through

through the holding mat 12. In the process of manufacturing catalyst device 7, in the process of containing the catalyst carrier 10 and the holding mat 12 in the outer cylinder 73, the holding mat 12 is wrapped around the catalyst 10 and then it is pressed into the outer cylinder 73 formed cylindrically in advance.

Therefore, the holding mat 12 contained in the outer cylinder 73 is in the compressed state and through the repulsive force of the fibers that make up the holding mat 12, a compressive force acts between the catalyst carrier 10 and the holding mat 12 and between holding mat 10 and outer cylinder 73.. Since the catalyst carrier 10 is formed of a porous ceramic material, the surface roughness on the outer surface 11 is high and the surface of the holding mat 12 is also a rough face.

Therefore, the catalyst carrier 10 and the holding mat 12 are maintained so as not to move relative to each other by the frictional force.

Also, the holding mat 12 and the outer cylinder 73 are held together by friction.

As mentioned above, the outer cylinder 73 has its surface formed by a material that can be oxidized relatively easily.

In this way, the inner surface of the outer cylinder 73 is easily oxidized and a portion not in contact with the exposed and holding mat 12 is oxidized particularly easily.

Also, the holding mat 12 is a collection of fibers and has no air tightness close to perfection and thus the portion in contact with the holding mat 12 on the inner face of the outer cylinder 73 is also easily oxidized.

Therefore, if the catalytic converter 7 is contained in the exhaust silencer 75 and attached to a motorcycle or automobile, when the exhaust gas communicates through the interior of the catalyst converter 7 with the beginning of use, the inner face of the external cylinder 73 it is oxidized by the influence of the oxidizing gas contained in the exhaust gas or heat of the exhaust gas.

Then, on the inner face of the outer cylinder 73, oxide layers

73A and 73B are quickly formed after the use of the catalyst device 7 starts. The oxide layer 73A is located on the upstream side with

- relation to the flow of the exhaust gas indicated by the symbol D in figures 15 and 5 in a place where the inner face of the external cylinder 73 is exposed to the unpurified exhaust gas.

The unpurified exhaust gas contains oxidizing gases such as NOx (nitrogen oxides), oxygen or the like and the inner surface of the outer cylinder 73 is oxidized by these oxidizing gases, with which the 73A oxide layer is formed. 10 Also, the downstream side of the catalyst conveyor 10 with respect to the discharge gas flow indicated by the symbol D is a place exposed to the exhaust gas having passed through the catalyst conveyor 10 and purified, but the exhaust gas The purified material also contains the oxidizing gases, such as oxygen, so the inner surface of the outer cylinder 15 is oxidized by these oxidizing gases and the oxide layer 73B is formed.

Furthermore, since the interior of the catalyst device 7 reaches a temperature that is considerably high by the heat in the exhaust gas, the oxidation reaction on the inner surface of the outer cylinder 73 is stimulated.

The temperature inside the catalytic converter 7 is different depending on the displacement or model of the internal combustion engine, the type of fuel and the position of the catalyst converter 7 in the discharge path, but the temperature reaches a sufficient degree that the oxidation dation of the material of the outer cylinder 73 described above progresses rapidly.

Therefore, on the inner face of the outer cylinder 73, particularly the exposed portion is rapidly oxidized after the start of the use of the catalyst device 7, with which the oxide layers 73A and 73B are formed.

Also, on the inner face of the outer cylinder 73, oxidation progresses not only in the oxide layers 73A and 73B, but also in a place covered by the retention mat 12 and the oxide layers 73A and 73B are also formed by the expansion to a place in contact with the

retention structure 12. The oxidation on the inner face of the outer cylinder 73 does not progress under a uniform condition, but is subjected to the influence of a temperature

"uneven texture within the catalyst device 7 and moreover, the type, concentration, ratio of composition of the oxidizing gas contained in the discharge gas are not constant.

Therefore, on the inner face of the outer cylinder 73, an uneven oxidation reaction progresses and the oxide layers 73A and 73B have surfaces with high surface roughness.

Therefore, the coefficient of friction between the holding mat 12 and 10 the oxide layers 73A and 73B is extremely high and it is not easy to displace the positions of the holding mat 12 and the outer cylinder 73. In other words, the holding mat 12 is firmly held by / fixed to the outer cylinder 73 by friction.

Here, since high friction is generated by the oxide layers 15 73A and 73B formed in the portion where the end portion of the retaining mat 12 is in contact with the outer cylinder 73, the retaining mat 12 is maintained and secured together with the catalyst carrier 10, but even if the oxide layers 73A and 73B are formed only in the portion not in contact with the holding mat 12, the holding mat 12 can be maintained and fixed.

For example, when the oxide layer 73B is formed only in the portion without contact with the holding mat 12, if the holding mat 12 is to be displaced by the pressure of the exhaust gas indicated by the symbol D, the portion end of the retaining mat 12 is quickly brought into contact with the oxide layer 73B, thereby causing strong friction.

In this way, the holding mat 12 is held by the frictional force in a substantially difficult displaced position.

Therefore, since at least part of the inner surface of the outer cylinder 73 is oxidized and the oxide layer with high surface roughness is formed, the retaining mat 12 is held by and fixed on the outer cylinder 73 with the conveyor. catalyst 10. As mentioned above, the holding mat 12 is pressed

into the outer cylinder 73 and the reaction force acts against the outer cylinder 73. Thus, in addition to the friction coefficient increased by oxidation of the outer cylinder 73 into the oxide layers 73A and "73B, a force acts between the holding mat 12 and the outer cylinder 73, 5 thereby the frictional force between the holding mat 12 and the oxide layers 73A and 73B is further increased.

Therefore, the holding mat 12 is held firmly by and securely attached to the outer cylinder 73. Also, the material that forms the outer cylinder 73 is, unless it is worked to make the surface physically rough, a relatively flat face. smooth before use as the catalyst device 7 is initiated.

In this way, since the surface roughness of the outer cylinder 73 is small and the friction coefficient is low during the manufacturing process of the catalyst device 7, in the process of pressure adjustment of the holding mat 12 and the catalyst conveyor 10 for inside that external cylinder 73, pressure adjustment can be carried out smoothly without a problem.

Then, when the holding mat 12 and the catalyst carrier 10 are contained in the outer cylinder 73 in order to become the catalyst device 7 and its use is initiated, the inner face of the outer cylinder 73 is quickly oxidized and oxide layers 73A and 73B with high surface roughness are formed, thus retaining mat 12 is maintained by and fixed on the outer cylinder 73 together with the catalyst conveyor 10. Thus, in the catalyst device 7, without a special operation, the holding mat 12 can be attached to the outer cylinder 73 and the displacement between the holding mat 12 and outer cylinder 73 can be prevented.

Like the material of the outer cylinder 73, several materials that satisfy the conditions described above can be mentioned, but in view of the strength, machinability, ease to be oxidized, smoothness on the surface before the use of the catalyst device 7 is started, weight and so before, among the materials that can be oxidized more easily than stainless, iron materials such as general carbon steels (SP materials),

aluminum, aluminum alloys and so on can be cited, for example.

It is preferable that these materials do not have a passive or similar oxidized film formed on the surface.

By the use of such materials, there is an advantage that oxidation progresses rapidly even at a low temperature and oxide layers 73A and 73B are formed and even if the catalytic device 7 is disposed in the exhaust pipe of an engine. internal combustion with small displacement or even if the discharge temperature does not rise much, the retaining mat 12 can be fixed on the outer cylinder 73. 10 It is not necessary that the entire outer cylinder 73 be formed of a material that can be oxidized as above, but only a portion of the oxide layers 73A and 73B shown in figure 15, a portion in contact with the end portion of the holding mat 12 or the proximity of the end portion of the holding mat 12 can be formed by the above materials.

Even in this case, since the oxide layer is formed in a portion in contact with the retaining mat 12 or in the vicinity of the end portion of the retaining mat 12, the retaining mat 12 can be held by and attached to the outer cylinder 73. On a motorcycle, the catalytic converter could be formed using a metal carrier such as a drilling metal or a metal socket worked in an alveolar shape by the curvature of a metal plate.

This metal conveyor is different from the case of the ceramic conveyor, but it can be attached to the external cylinder by means of an angled or similar support installed upright inside the external cylinder, for example, without using a mat.

Also, the external cylinder containing the metal conveyor is placed in a silencer in general similar to the catalyst device of the seventh modality.

In this case, the temperature difference between the center and the outer cylinder portion of the metal conveyor is small and a specific temperature difference is approximately 100 to 150 ° C, for example, and if the center of the conveyor is at 900 ° C, for example, the temperature of the outer cylinder is 750 to 800 ° C.

Therefore, like the material of the outer cylinder, a stainless material could be used as a material with high oxidation resistance and high temperature resistance.

In contrast, in the seventh embodiment, since the catalyst device 7 is formed using the catalyst carrier 10 made of ceramics, the holding mat 12 is placed between the outer cylinder 73 and the catalyst carrier 10. Since this holding mat 12 functions as an insulating material, the temperature difference between the outer cylinder 73 and the catalyst carrier 10 is as large as 250 to 500 ° C, for example and even if the temperature in the center of the catalyst 10 carrier 10 exceeds 10000 ° C, the temperature of the outer cylinder 73 is approximately 600 ° C.

Therefore, by placing the holding mat 12 between the catalyst carrier 10 made of ceramic and the outer cylinder 73, the heat of the outer cylinder 73 can be adjusted and the oxidation progress can be suppressed appropriately.

In this way, as the material of the outer cylinder 73, a material other than stainless, such as aluminized steel sheet or the like, can be applied.

Therefore, the effect in which the manufacturing cost can be kept low can be obtained.

Also, in the seventh modality, since the catalytic device 7 is disposed within the cylindrical main body 120 of the exhaust muffler 75, even if the oxidation of the external cylinder 73 of the catalytic device 7 progresses properly, this is not shown in appearance.

As a result, by using the catalyst device 7 explained in the seventh modality for a small vehicle such as a motorcycle, the unloading system can be built compact and it is effective that the support of the catalyst 10 carrier made of ceramic is reinforced while a low-priced material other than stainless material (SUS430 above or similar) is used.

A method of manufacturing the catalyst device 7 will be described below.

The catalyst device 7 can be manufactured by a method 30 explained in the fourth to sixth modes described above similarly to the catalyst device 1. Also, the device can be manufactured by the following methods.

Various conditions, such as temperature, time and so on in the following explanations indicate only specific examples and do not limit the contents of the present invention.

First, a portion of an end in the axial direction of the cylindrically formed catalyst carrier 10 is immersed in a solution containing platinum, rhodium and palladium for a predetermined length (depth). Then, at the other end of the catalyst carrier 10 in the state in which one end is immersed, a tube connected to a pump that can pump the solution up is connected.

This tube is connected to the other end of the catalyst 10 carrier so that suction can be performed from everyone. the fine pores 5. Then, by performing the suction by the pump through the tube, the solution is pumped upwards from all the fine pores 5, the solution is placed in contact with the surface of each fine pore 5 and the talisator, which is a solute, adheres to the surface of each fine pore 5. Here, 15 since the catalyst carrier 10 has an end immersed in the solution for the predetermined length in the process of inducing the adhesion of the solution on the surface of each pore fine 5, the solution adheres to part of the outer surface 11 of the catalyst carrier 10 through the predetermined length. 20 After that, the catalyst carrier 10 is lifted from the solution and dried by hot air at 100 ° C for 10 minutes and then sintered at 450 ° C for 1 hour and the catalyst carrier 10 is created to transport the catalyst.

After sintering, by wrapping the holding mat 25 12 around the outer surface 11 of the catalyst carrier 10 and compressing the catalyst carrier 10 into the outer cylinder 73 together with the holding mat 12, the catalyst device 7 is formed.

In the above process, the solution in which the catalyst carrier 10 is created to transport palladium, rhodium and polyol and the material used for this solution are similar to those described in the fourth embodiment.

Also, after the holding mat 12 and the catalyst carrier 10 are pressed into the outer cylinder 73, it is possible! further heat the catalyst device 7 in order to join the retaining belt "in the outer cylinder 73. That is, the catalyst device 7 can

- be heated in the state in which the catalyst carrier 10 is contained 5 together with the holding mat 12 in the outer cylinder 73 so as to form the catalyst device 7. In that case, provided that the holding mat 12 and the inner face of the outer cylinder 73 are heated in a state of close contact, the affinity between the inner face of outer cylinder 73 and the holding mat 12 is further improved and placed in close contact, induced to adhere or joined to such a degree that the force of predetermined retention is exercised. cida.

Then, if an additive material with the same composition as the material that forms the retaining mat 12 or a composition containing a common element with the material is added to the inner face of the outer cylinder 15, provided that the affinity between the retaining mat 12 and the outer cylinder 73 is high, even if the heating temperature is not so high, the holding mat 12 and the outer cylinder 73 can be placed in close contact, induced to adhere or tightly joined.

As a specific example, if the holding mat 12 is formed by the compression or integration of fibers made from alumina (aluminum oxide), which is a type of ceramic, using aluminum or an alloy containing aluminum for the outer cylinder 73 or by formation of the external cylinder 73 by iron, stainless or other metals and then, by the application of aluminum plating on the internal face of the external cylinder 73, the holding mat 25 12 and the external cylinder 73 are placed in close contact, induced to adhere or join during heating by the affinity between the aluminum contained in each, even if the heating temperature is low.

As described above, according to the seventh embodiment in which the present invention is applied, provided that the catalyst carrier 10 is made of ceramic that carries a catalyst inside, the outer cylinder 73 containing the catalyst carrier 10 and the retaining mat 12 placed between the outer cylinder 73 and the catalyst carrier

10 are supplied and at least on a part of the inner surface of the outer cylinder 73, a material that can be oxidized more easily than the stainless material in the exhaust gas of the internal combustion engine _ is disposed, the material on the inner face the external cylinder 73 is oxidized with the use of the catalytic device 7, and the oxide layers 73A and 73B are formed, thus the surface roughness is increased.

Thus, since the friction coefficient is high at least in part of the outer cylinder 73, the holding mat 12 and the catalyst carrier 10 can be frictionally fixed between the outer cylinder 73 and the holding mat 12. 10 Also , since oxidation has not progressed much on the in- face. external cylinder 73 before use as the catalyst 7, the surface roughness is not high.

Thus, in the process of compressing the catalyst carrier 10 together with the holding mat 12 into the outer cylinder 73, the pressure adjustment can be carried out smoothly.

Then, after the use of the catalyst device 7 is initiated, the material disposed in the external cylinder 73 is exposed to the exhaust gas and quickly oxidized by the influence of the oxidizing gas in the exhaust gas and / or high temperature of the exhaust gas and the oxide layers 73A and 73B are formed, thus the surface roughness is increased.

Therefore, the holding mat 12 and the catalyst carrier 10 can be fixed quickly after the start of use.

As mentioned above, according to the configuration of the seventh embodiment, the holding mat 12 and the catalyst conveyor 10 can be fixed to the outer cylinder 73 with a simple configuration without incurring problems 25 in the containment process of the catalyst conveyor. 10 and the holding mat 12 on the outer cylinder 73. Furthermore, the material that can be easily oxidized arranged at least on part of the inner face of the outer cylinder 73 is a material in which the oxidation progresses at a lower temperature than the temperature at which the stainless material (SUS430 or similar) is oxidized in the exhaust gas of the internal combustion engine.

Thus, due to the material's disposition, in which the oxidation progresses at a lower temperature in the exhaust gas, on the inner face of the external cylinder 73, the material is quickly oxidized and the surface roughness becomes high if exposed to the exhaust gas. and even in an environment where the exhaust gas

_ the load cannot reach a high temperature easily, the retaining belt 12 and the catalyst conveyor 10 can be fixed quickly after it is exposed to the exhaust gas.

Also, by using a general carbon steel (SP) material as the material disposed on the inner face of the outer cylinder 73, the configuration in which the catalyst conveyor 10 and the holding mat 12 can be easily fixed it can be easily accomplished using carbon steel, which is an inexpensive material with excellent machinability.

Then, as the material disposed on the inner face of the outer cylinder 73, by using the material in which an additive material of the same composition as the material that forms the retaining mat 12 or the composition containing a common element such as the material is added in order to have a configuration in which the material is arranged in a position in contact with the holding mat 12 on the inner face of the outer cylinder 73, the affinity between the holding mat 12 and the outer cylinder 73 is improved so that the holding mat 12 and the outer cylinder 73 can be fixed so that they do not move with respect to each other.

Also, by heating the catalyst device 7 after being formed in that case, the holding mat 12 and the inner face of the outer cylinder 73 can be induced to adhere to each other favorably and the holding mat 12 and the catalyst carrier 10 can be fixed.

Here, the ratio of the length and diameter of the catalytic converter 7 when the catalyst converter 7 of the seventh embodiment is attached to the exhaust silencer 75 as shown in figure 13 and attached to a motorcycle will be described.

Figure 16 is a graph showing the correlation between a high temperature resistance and the deformation resistance of the external cylinder 73 and the shape of the catalyst carrier 10. In figure 16, the reference letter W represents the diameter of the catalyst carrier 10, the reference letter L represents the length of the catalyst carrier 10 in the axial direction.

Also, the graph shows the high temperature resistance and the deformation resistance "of the external cylinder 73. 5 As shown in figure 16, the deformation resistance of the external cylinder 73 is fluctuated according to the ratio between the diameter W and the length L of the catalyst carrier 10, and the shorter the length L in relation to the diameter W, the greater the deformation resistance.

Since the deformation resistance of the outer cylinder 73 is preferably a reference value or more in the case of L / W = 1.5 as shown in the figure, it is preferable that the diameter W and the length L satisfy the ratio of Lm R 1.5. On the contrary, in a region of 1.5 <ljW, since the high temperature resistance and the deformation resistance in the external cylinder 73 are low, it is preferable that the catalyst device 7 15 is not located within this region. That is, if the catalyst device 7 of the seventh modality is to be fixed to the exhaust silencer 75 as shown in figure 13 and attached to a motorcycle, the diameter W and length L of the catalyst carrier 10 satisfy the requirements above and in this case W = 40 mm, for example, L = 60 to 120 mm is preferable.

The seventh modality above shows an aspect in which the present invention is applied and the present invention is not limited to the above modality.

For example, in the seventh embodiment, all or part of the outer cylinder 73 is explained to be formed by a material that can be oxidized more easily than stainless material such as general carbon steel, but it can be so It is configured that the outer cylinder 73 is formed by a plurality of layers and only one exposed layer on the side of the holding mat 12 is formed by the above material.

Furthermore, in the above modality, patin, rhodium and palladium are explained to be transported by the catalyst 10 carrier, but other catalyst substances such as iridium, cerium oxides and so on can be transported.

The shape of the outer cylinder 73 is not limited to a cylinder, but it can be a shape having an oval or polygonal sectional shape as long as it is a hollow pipe. Also, the retaining mat 12 is not limited to covering the entire outer surface 11 of the conveyor _ of the catalyst 10, but a part of the outer surface 11 can be exposed 5 without being covered by the retaining mat 12. Needless to say that the other detailed settings can be changed arbitrarily. Eighth modality Fig. 17 is a diagram that schematically illustrates a discharge silencer 106 provided with a catalyst device 8 of steel matched with an eighth modality. The discharge silencer 106 is arranged

B on a motorcycle similar to the exhaust muffler 100 (figure 1) and works as a silencer that decompresses the exhaust gas at high temperature / high pressure having passed through the exhaust pipe 110 and discharges it to the outside. 15 The exhaust muffler 106 has a cylindrical main body 120 to which the exhaust pipe 110 is connected and the catalytic device 8 supplied with the catalyst carrier 10 is supported on the main cylindrical body 120. The catalyst device 8 has a cylinder external 83 instead of the external cylinder 13 of the catalytic device 1 (figure 1). The catalyst device 8 penetrates and is attached to the first bulkhead 131 closest to the end portion 11OA of the discharge pipe 110 similarly to the catalyst device 1. Here, the outer diameter of the outer cylinder 83 that constitutes the catalyst device 8 is formed Slightly wider than the outlet pipe 110 outer diameter, so that the extreme portion 11OA enters the outer cylinder 83 and is stable. Then, in the state in which the end portion 11OA enters the outer cylinder 83, an end portion 83A of the outer cylinder 83 is joined on the outer side face of the discharge pipe 110 by welding. In a joined portion 107, the end portion 83A and the discharge pipe 110 are directly joined together. Except for the configuration of the external cylinder 83 and the connected portion 107, the exhaust silencer 106 is constituted similarly to the silencer.

discharge method 100 and the catalytic device 8 is constituted similarly to the catalyst device 1 (figures 1 and 2), except that the external cylinder 83 is provided instead of the external cylinder 13 (figures 1 and 2). In this eighth modality, portions configured similarly to the first to sixth modalities are indicated with the same reference numerals and the description will be omitted.

The catalyst device 8 has a configuration in which the outer cylinder 13 in the catalyst device 1 shown in figure 2 is replaced by the outer cylinder 83, supplied with the catalyst carrier 10, which is a cylindrical porous alveolar structural body and the trans - catalyst carrier 10 around which the holding mat 12 is wrapped is contained in the cylindrical outer cylinder 83. The outer cylinder 83 is a hollow pipe with a circular section, for example and both ends are open.

The material that forms the outer cylinder 83 is a material with a coefficient of linear expansion less than that of the stainless material (JlS SUS430 or similar, for example). The coefficient of linear expansion (coefficient of linear expansion over a temperature range including a normal temperature.

The same applies to the following) of the stainless material is 10 x 10g / ° C (ferrite stainless steel) at 17 x 10 "¶ ° C (austenite stainless steel), and the linear expansion coefficient of SUS 430 mentioned as an example the stainless material is 10.4 x 10 "¶ ° C and the linear expansion coefficient of SUS304 is 17 x 10" ¶ ° C.

The material forming the outer cylinder 83 has a lower Iinear expansion coefficient and preferred examples include either pure titanium, titanium alloy or titanium compound, or an alloy containing any or more pure titanium, titanium alloy and compound of titanium.

The linear expansion coefficient of titanium (JIS class 1 to class 4 of pure titanium) is 8.4 x 10O ^ / ° C and the T1-6AI-4V alloy mentioned as an example of the titanium alloy has the coefficient - 8.8 x 10 0 ° C linear expansion element and any other titanium alloys have linear expansion coefficients less than that of stainless materials.

Here, the material that forms the outer cylinder 83 includes titanium alloys

tannin such as alloy [], alloy lj-lj, alloy [je so on or pure titanium (JlS class 1 to class 4) and the titanium alloy contains any one or more of other metals such as aluminum (Al), silicon (Si), iron (Fe), copper (Cu), tin "(Sn), vanadium N), niobium (Nb), molybdenum (Mo), chromium (Cr), zirconium (Zr) and 5 so on together with titanium (Ti) and other unavoidable impurities that may be contained and what's more, those containing oxygen (O) and so on can be cited.

Specifically, T1-6AI-4V, Ti-6Al-6V-2Sn, Ti- 6Al-2Sn-4Zr-6Mo, T1-1.5AI, Ti-1OV-2Fe-3Al, T1-7AI-4MO, Ti-5Al- 2.5Sn, T1-6AI-5Zr-0.5Mo-0.2Si, Ti-5.5Al-3.5Sn-3Zr-0.3Mo-1 Nb-0.3Si, T1-8AI-1 Mo-lV, TiLO 6Al-2Sn-4Zr-2Mo, Ti-5AI-2Sn-2Zr-4MoACr, Ti-11,5Mo-6Zr-4,5Sn, Ti-15V-. 3Cr-3AI-3Sn, Ti-15Mo-5Zr-3Al, Ti-15Mo-5Zr, Ti-13V-11Cr-3Al and so on can be used.

Also, a material made of pure titanium or titanium alloy containing fine particles of silicon carbide (SiC), boron carbide (B4C and so on), glass, iron oxide and so on can be used.

These materials all have lower linear expansion coefficients than the stainless material as mentioned above.

Furthermore, the materials listed above and the material containing any other titanium are lighter than the stainless material.

Although the density 20 (specific weight) of SUS430 as an example of the stainless material is 7.98 g / cmj the density of titanium (JlS class 1 to class 4 pure titanium) is 4.5 g / cm 'and the density of Ti-6AI-4V alloy as an example of the titanium alloy is 4.4 g / cm3. In this way, the catalytic device 8 formed using the outer cylinder 83 is light and if the catalytic device 8 is installed on a motorcycle or a car, advantageous effects such as reducing the weight of the car's chassis weight, improves freedom of car chassis design, improved handling / machining performance and so on can be obtained.

Figure 18 is a sectional view of the catalyst device 8. 30 As shown in figure 18, the catalyst device 8 is configured such that the outer surface 11 is held by the outer cylinder 83 through the holding mat 12. In the process manufacture of that device

v catalyst 8, in the process of containing the catalyst carrier 10 and the holding mat 12 on the outer cylinder 83, the holding mat 12 is wrapped around the catalyst carrier 10 and then it is "pressed into the outer cylinder 83 formed cylindrically with 5 anticipation.

Therefore, the holding mat 12 contained in the outer cylinder 83 is in the compressed state and through the repulsive force of the fibers that make up the holding mat 12, the compressive force acts between the catalyst carrier 10 and the holding mat 12 and between the holding track 12 and the outer cylinder 83. 10 Since the catalyst carrier 10 is formed by one. porous ceramic material, the surface roughness on the outer surface 11 is high and the surface of the holding mat 12 is also a rough face.

Therefore, the catalyst carrier 10 and the holding mat 12 are maintained so that they do not move relative to each other by the force of friction.

Also, the holding mat 12 and the outer cylinder 83 are held in predetermined positions on the outer cylinder 83 by friction against the pressure of the exhaust gas in the direction indicated by the symbol H in the figure.

This catalyst device 8 can be manufactured using the external cylinder 83 instead of the external cylinders 13 and 73 by the method of manufacturing the catalyst device 7 explained in the seventh modality and the manufacturing method of the catalyst device 1 explained in fourth through sixth modalities described above. That is, by wrapping the retaining belt 12 around the outer surface 11 of the catalyst carrier 10 manufactured by the above method, that catalyst carrier 10 is pressed into the outer cylinder 83 together with the retaining belt. 12 in order to form the catalyst device 8. In this manufacturing method, the solution to have palladium, rhodium and platinum loaded by the catalyst carrier 10 and the materials used in this solution is the same as that described in the fourth modality. 30 After the holding belt 12 and the catalyst conveyor 10 are pressed into the outer cylinder 83, it is possible to heat the catalyst device 8 further in order to join the holding belt

12 and the outer cylinder 83. In this case, the retaining mat 12 and the inner face of the outer cylinder 83 are heated in the state of close contact so as to be placed in close contact, induced to adhere or joined together until such time. degree that a predetermined holding force is exerted. 5 In the eighth mode, the outer cylinder 83 formed cylindrically in advance is used, but methods such as potting and winding and tightening can also be used.

In order to contain the catalyst conveyor 10 by potting, the catalyst conveyor 10 around which the holding mat 12 is wound is surrounded by parts divided into the forms that the cylinder is applied with a plurality of parts to. along the axial direction, and the split parts are joined by welding, adhering, screwing and so on to form the outer cylinder 83. In this method, when the plurality of split parts are joined, the split parts are pressed together in order to compress the holding mat 12. In this way, the catalyst carrier 10 and the holding mat 12 are held in predetermined positions in the outer cylinder 83 by the repulsive force of the holding mat 12 in the state contained in the outer cylinder 83. Also, in order to contain the catalyst carrier 10 by winding and tightening, a sheet material used as an outer cylinder material 83 is wrapped around the catalyst carrier 10 around which the retaining mat 12 is wound and the end portions of the sheet material are joined together by welding, adhering, screwing and so on to form the cylindrical outer cylinder 83. In this method, during the process of winding the sheet material, the tension that compresses the holding mat 12 is applied to the sheet material.

Therefore, the catalyst carrier 10 and the holding mat 12 are held in predetermined positions on the outer cylinder 83 by the repulsive force of the holding mat 12 in the state contained in the outer cylinder 83. As long as the catalyst that purifies the exhaust gas is ex - placed on the high temperature exhaust gas, the influence of the expansion of a container containing the catalyst carrier 10 must be considered.

The catalyst carrier 10 can be maintained in the container using a retaining element in a complicated shape for this purpose, but in this case, a process for making the retaining element according to the size of the catalyst carrier 10 it is required and a problem is caused as the number of manufacturing processes is increased.

Also, making such a retaining element is not easy.

The configuration explained in the eighth modality is planned, in view of the above problems, to carry out the configuration that can keep the catalyst carrier 10 stable even in a high temperature environment in the configured catalyst device 8 containing the catalyst carrier 10 in the container without incur an increase in manufacturing processes or complication of configuration.

The catalyst device 8 in the eighth embodiment and the catalyst device 9, which will be described later in the ninth and tenth embodiments include the ceramic catalyst carrier 10 that carries the catalyst purifying the exhaust gas from the internal combustion engine, the outer cylinder 83 which contains the catalyst carrier 10 and the holding mat 12 placed between the outer cylinder 83 and the catalyst carrier 10 and characterized in that the outer cylinder 83 is made of a material with a linear expansion coefficient less than that of stainless material.

In the catalyst device 8 configured as above, if being disposed in the exhaust silencer 106 for use as shown in figure 17, for example, the high temperature exhaust gas passes through the interior, thereby the catalyst conveyor 10, the conveyor belt retainer 12 and outer cylinder 83 are all exposed to high temperature.

The ceramics that make up the catalyst carrier 10 and the holding mat 12 have an extremely small linear expansion coefficient and like the honeycomb catalyst carrier made of ceramics, for example, those with the linear expansion coefficient of approximately 1.2 x iO "¶ ° C are known.

Thus, in the state in which the catalyst device 8 is at a high temperature, the catalyst carrier 10 and outer cylinder 83 are expanded at different rates, the free span between the catalyst carrier 10 and outer cylinder 83 is expanded. extended and it is likely that the holding force of the catalyst carrier 10 by the repulsive force of the

"retention mat 12 is weakened. 5 However, in the catalyst device 8 in the eighth modality, since the outer cylinder 83 is formed by a material with a linear expansion coefficient less than that of the stainless material (JlS SUS430 or similar , for example) as mentioned above, the expansion of the outer cylinder 83 by heat is extremely small, there is no fear 10 that the free span will be generated between the catalyst carrier 10 with a "low linear expansion coefficient and the holding mat 12 or the repulsive force of the holding mat 12 is noticeably decreased.

In this way, even though the catalyst device is exposed to a high temperature of the exhaust gas, in which the holding performance of the catalyst 10 carrier 15 is rarely changed from the state at a normal temperature.

As a result, there is no need to provide a projection or separate element to secure or lock the catalyst carrier 10 so that it is not moved on the outer cylinder 83 as a preparation for the case in which the holding force by holding belt 20 is reduced.

Therefore, the catalyst carrier 10 and the holding mat 12 can be maintained with stability even if it is exposed to the heat of the exhaust gas without complicating the structure.

Also, the shape of the outer cylinder 83 is a simple cylinder that satisfies the requirements for containing the catalyst carrier 10 and the holding mat 12 and other complicated shapes are not necessary.

In this way, the number of processes required for the manufacture of the outer cylinder 83 is no different from that in the case of the manufacture of the outer cylinder 83 by a material such as stainless or iron, for example.

As mentioned above, by using a material with a coefficient of expansion 30 are linearly less than that of the stainless material for the material of the outer cylinder 83, a catalyst device 8 that can steadily maintain the catalyst carrier 10 and the retention mat 12 even at a high temperature can be carried out easily without using a complicated structure or without incurring an increase in the number of manufacturing processes and mechanism complication.

Particularly, as explained in the eighth modality, if the material of the outer cylinder 83 is any of pure titanium, titanium alloy and titanium compound or an alloy containing any or more of pure titanium, titanium alloy and compound of titanium, the linear expansion coefficient of the outer cylinder 83 is drastically lower than that of the non-rusting materials and so on and the amount of deformation caused by the expanse when it is exposed to the high temperature exhaust gas during use can be extremely small.

Therefore, since the catalyst 10 carrier retention performance is rarely changed even in a high temperature environment, the precision required to guarantee the catalyst 10 conveyor retention performance, that is, the accuracy range allowable is increased, which provides the advantage that freedom in design and manufacture is improved.

Furthermore, either pure titanium, titanium alloy and titanium compound or an alloy containing any or more pure titanium, titanium alloy and titanium compound cited as the material for the outer cylinder 83 has the advantage high melting point and no problem is caused even if it is installed in a position close to the internal combustion engine in the discharge path and can be used for a long time even in an environment exposed to the exhaust gas at high temperature.

The above materials have the advantage of Ieve weight and advantageous effects can be obtained, such as reducing the weight of the car chassis weight, improving the design freedom of the car chassis, improving handling / machinability performance and so on being installed on a motorcycle or an automobile, for example.

Ninth embodiment Figure 19 is a sectional view illustrating the structure of the exhaust pipe 140 according to a ninth embodiment.

In the ninth modality, portions configured similarly to the first to seventh modalities and the eighth modality are indicated with the same reference numerals and the description will be omitted.

The structure of the exhaust pipe 140 shown in figure 19 consists of the union of a discharge pipe 90 made of titanium on the side of 5 an engine (not shown) of the catalyst device 8 and the union of a discharge pipe 92 made of titanium on the side of a discharge silencer (not shown) on the catalytic converter 8. The structure of the exhaust pipe 140 is a conduit constituting a part of the discharge path that joins the engine discharge port and the discharge silencer, and 10 Actually, this is a pipe that connects a discharge manifold, one. collection pipe or both in the engine or in the exhaust silencer.

With regard to the discharge gas flow indicated by the symbol H, the discharge pipe 90 made of titanium is located on the side upstream of the catalytic device 8, while the discharge pipe 92 made of titanium is located in the 15 Downstream of the catalytic converter 8. The exhaust pipe 90 made of titanium is formed by a hollow pipe with a smaller diameter than that of the external cylinder 83, and a conical portion 91, whose diameter is gradually widened, is formed at an end portion of the discharge pipe 90 made of titanium, and the outer cylinder 20 is joined at the distal end of the conical portion 91. Also, the discharge pipe 92 made of titanium is a hollow pipe with the same diameter as that of the external cylinder 83. Also, the discharge pipe 90 made of titanium and the discharge pipe 92 made of titanium are both formed by a titanium material 25 similar to that of the external cylinder 83. That is, in the ninth modality, the external cylinder 83, the discharge pipe 90 made of titanium and the exhaust pipe 92 made of titanium are all formed by titanium alloys such as alloy 13, ljga Cljj, alloy [je so on or pure titanium (JIS class 1 to class 4) and alloy of titanium contains 30 any or more of other metals such as aluminum (Al), silicon (Si), iron (Fe), copper (Cu), tin (Sn), vanadium N), niobium (Nb), molybdenum (Mo) , chromium (Cr), zirconium (Zr) and so on along with titanium (Ti) and other

other unavoidable impurities that may be contained and furthermore, those containing oxygen (O) and so on can be cited.

Specifically, T1-6AI-4V, Ti-6Al-6V-2Sn, Ti-6Al-2Sn-4Zr-6Mo, T1-1.5AI, Ti-1OV-2Fe-3Al, T1-7AI-4MO, Ti- 5Al-2.5Sn, Ti-6Al-5Zr-0.5Mo-0.2Si, Ti-5.5Al-3.5Sn-3Zr-0.3Mo- 5 1Nb-0.3Si, T1-8AI-1MO-1V , Ti-6Al-2Sn-4Zr-2Mo, Ti-5AI-2Sn-2Zr-4MoACr, Ti-11,5Mo-6Zr-4,5Sn, Ti-15V-3Cr-3Al-3Sn, Ti-15Mo-5Zr-3AI , Ti-15Mo-5Zr, Ti-13V-11Cr-3AI and so on can be used.

Also, a material made of pure titanium or titanium alloy containing fine particles of silicon carbide (SiC), boron carbide (B4C and so on), glass, iron oxide and so on can be used. - The external cylinder 83, the discharge pipes 90 and 92 made of titanium are all preferably formed by the same material, considering the ease of welding, ease of availability of the material, the cost of manufacture and so on. however, a structure in which the outer cylinder 15, the discharge pipes 90 and 92 made of titanium are not permissible and the outer cylinder 83, the discharge pipes 90 and 92 made of titanium can be formed by different materials, as long as they are any of the materials containing the titanium described above. 20 As mentioned above, since the outer cylinder 83, the discharge pipes 90 and 92 made of titanium are all formed of either pure titanium, titanium alloy and titanium compound or an alloy containing any pure titanium alloy titanium and titanium compound, the discharge pipe 90 made of titanium and the external cylinder 83, as well as the external cylinder 83 and the discharge pipe 92 made of titanium can be joined in an easy and reliable way by welding, for example. This is, as shown in figure 19, the distal end of the conical portion 91 and the end portion 83A of the outer cylinder 83 have the same diameter and they are joined by the butt weld.

Also, the end portion 83B of the outer cylinder 83 and the distal end of the discharge tube 92 made of titanium have the same diameter and similarly joined by the top sealing.

Since welding between titanium-containing metal materials works well, joining can easily be done with sufficient strength.

In the structure of the discharge pipe 140 according to the ninth embodiment, in addition to the effect explained in the eighth embodiment described above, there is an advantage that the outer cylinder 83 containing the catalyst carrier 10 and the holding mat 12 in the catalyst device 8 it can be used as a part of the exhaust pipe structure 140. As a result, an external coating or the like to contain the catalyst device 8 is not necessary and the reduction in cost and weight can be scaled.

Also, since the exhaust pipes 90 and 92 made of titanium joined in the outer cylinder 83 are formed of either pure titanium, titanium alloy and titanium compound or an alloy containing any of pure titanium, titanium alloy and compound of titanium similar to outer cylinder 83, metals of the same or similar types are joined and they can be joined easily by welding or the like and high bond strength can be obtained.

Tenth embodiment Figure 20 is a sectional view illustrating the structure of the discharge pipe 140 according to the ninth embodiment.

In this tenth modality, portions configured similarly as the first to seventh, eighth and ninth modalities are indicated with the same reference numerals and the description will be omitted.

The structure of the exhaust pipe 141 shown in figure 20 is formed to have a discharge pipe 93 made of stainless steel attached to a motor shaft (not shown) of the catalytic device 9 and to have a discharge pipe 95 made of oxidizable joined to the exhaust silencer side (not shown) of the catalytic converter 9. The structure of the exhaust pipe 141 is a pipe constituting a part of a discharge path joining a discharge port for the engine and the exhaust muffler and specifically, this is a pipe that joins a discharge manifold, a pipe pipe or both in the engine or the exhaust muffler.

With respect to the discharge gas flow indicated by the symbol H, the discharge pipe 93 made of stainless is located on the upstream side of the catalytic device 9, while the discharge pipe 95 made of stainless is located on the downstream side of the catalyst device 9. 5 The catalyst device 9 is provided with an outer cylinder 84 instead of the outer cylinder 83 in the catalyst device 8 described above.

The outer cylinder 84 is a hollow cylindrical pipe formed from the same material as that of the outer cylinder 83. A difference from the outer cylinder 83 is that

- the end portion 84A on the upstream side and the end portion 10 84B on the downstream side with respect to the discharge direction H are worked, respectively, so as to be joined in the discharge pipes 93 and 95 made of stainless steel.

Also, the discharge pipes 93 and 95 made of stainless steel are both hollow pipes formed by a stainless material (SUS430, SUS304 15 or similar). In the portions joined between the discharge pipe 93 made of stainless and the external cylinder 84, as well as the external cylinder 84 and the discharge pipe 95 made of stainless, both discharge pipes 93 and 95 made of stainless have slightly smaller diameters than the outer cylinder 84 and enter the outer cylinder 84. By welding the connecting parts 94 and 96 in this state, the outer cylinder 84 and the exhaust pipe 93 made of oxidizable, as well as the outer cylinder 84 and the discharge pipe 95 made of stainless are joined together.

Figures 21 are enlarged views illustrating a configuration of the portion connected to the structure of the discharge pipe 140, in which figure 25 21A shows the portion joined between the discharge pipe 93 made of stainless steel and the external cylinder 84 and the figure 21B shows the portion joined between the outer cylinder 84 and the discharge pipe 95 made of stainless.

As shown in figure 21A, a hole 84C is formed in the end portion 84A, which is an opening end on the upstream side 30 of the outer cylinder 84. Hole 84C is a hole that penetrates from the outer cylinder 84 and is formed in plural with a predetermined interval along the circumferential direction of the opening edge of the outer cylinder 84.

An end portion 93A of the discharge pipe 93 made of stainless enters the end portion 84A deeper than the hole 84C, and in that state, a connecting piece 94 is added to the end portion 93A.

The connecting piece 94 is a metal piece having a shape 5 that passes through the hole 84C from the outside of the outer cylinder 84 and placed in contact with the end portion 93A and is formed by the same stainless material as that of the pipe. discharge 93 made of stainless.

The end portion 93A and the connector 94 are welded. 10 of the joints by the projection solidity. This is, in the state in which the connector 94 is inserted into hole 84C, the connector 94 and the discharge pipe 93 made of stainless are electrified and they are joined by the generation of heat in their contact portion.

By this method, the connector 94 is welded to the end portion 93A through all the holes 84C arranged in the end portion 84A.

Here, the plurality of joining pieces 94 are joined, but the plurality of joining pieces 94 can be connected together or they can be small independent pieces.

On the other hand, as shown in figure 21B, at end portion 84B, which is an opening end on the downstream side of outer cylinder 84, a hole 84D is formed.

Hole 84D is a hole penetrating the outer cylinder 84 and formed in plural with a predetermined gap along the circumferential direction of the opening edge of the outer cylinder 84. An end portion 95A of the discharge pipe 95 made 25 stainless steel enters end portion 84B deeper than hole 84D, and in that state, a joining piece 96 is welded to end portion 95A.

The connecting piece 96 is a metal piece having a shape passing through the hole 84D from the outside of the outer cylinder 84 and placed in contact with the end portion 95A and is formed by the same stainless material as the discharge pipe 95 made of stainless.

Then, the end portion 95A and the connecting piece 96 are welded by the projection weld. This is, in the state in which the connector 96 is inserted into hole 84D, the connector 96 and the discharge pipe 95 made of stainless are electrified and they are joined by the generation of heat in their contact portion.

By this method, the connector 96 is released in the end portion 95A through all the holes 84D arranged in the end portion 84B.

Here, the plurality of connecting pieces 96 is joined, but the plurality of connecting pieces 96 can be connected together or they can be small independent pieces.

P In the structure of the discharge pipe 141, the outer cylinder 84 made 10 of a material containing titanium and the discharge pipes 93 and 95 made of stainless must be joined.

In the union of these different types of metals, the holes 84C and 84D are arranged in the end portions 84A and 84B of the outer cylinder 84 and the connection pieces 94 and 96 are joined in the discharge pipes 93 and 95 made of stainless using these holes 84C and 84D.

According to this method, the external cylinder 84 and the discharge pipes 93 and 95 made of stainless steel can be easily joined with sufficient resistance by welding the same type of metal.

The catalyst device 9 consists of the catalyst carrier 10 and the holding mat 12 on the outer cylinder 84 made 20 of a material with a linear expansion coefficient less than that of the stainless material similar to the catalyst device 8 described above. to.

In this way, the advantages explained in the eighth and ninth modalities described above can be obtained.

In addition, in the structure of the discharge pipe 141, by using 25 cheaper discharge pipes 93 and 95 made of stainless steel, the structure can be made at a lower cost.

In this exhaust pipe structure 141, too, there are advantages as explained in the above ninth modality, that is, the advantages that the outer cylinder 84 to contain the catalyst carrier 10 and the holding mat 12 can be used as a part of the structure of the discharge pipe 141, an external coating or the like to contain the catalyst device 9 is not necessary and the reduction of cost and weight can be stimulated.

Also, the union between the outer cylinder 84 and the discharge pipes 93 and 95 made of stainless steel, which is the union between different types of metals, can be performed easily and reliably by a projection welding method forming the holes 84C and 84D in the end portions 84A and 84B of the outer cylinder 84 and the application of the connection parts 94 and 96 from the outside.

Also, the octave to the tenth modalities show only one specific aspect and can be changed arbitrarily.

For example, in the octave to tenth modalities, the shape of the outer cylinders 83 and 84 is explained as being cylindrical, but the present invention is not limited to this, and it can have an oval or polygonal sectional shape as long as it is a pipe hollow.

Eleventh embodiment Figures 22 and 23 are sectional views of an exhaust muffler 400 provided with a ceramic catalyst device 4 according to an eleventh embodiment.

This exhaust muffler 400 is connected to a rear end of the extended exhaust pipe 410 of a motorcycle engine and acts as a silencer that depresses the exhaust gas having passed through that exhaust pipe 410 and discharges it to the outside.

The exhaust muffler 400 has a cylindrical main body 420 to which the single extended exhaust pipe 410 of the engine is connected and the ceramic catalytic device (hereinafter referred to as a catalytic device) 1 supplied with a catalyst carrier 40 made of cement. ceramic is supported on this main cylindrical body 420. This main cylindrical body 420 is provided with an outer cylinder 421 constituting an outer circumferential face of that main cylindrical body 420, an inner cylinder 422 to be inserted into this outer cylinder 421 and a portion front wall 423 and a rear wall portion 424 substantially bulge connected to cover an opening of the front portion and an opening of the rear guard of these cylindrical elements 421 and 422.

The internal space formed by this inner cylinder 422, the front wall portion 423 and the rear wall portion 424 are divided into a plurality of (three in this example) expansion chambers (hereinafter referred to as a first expansion chamber P, a second expansion chamber 5 are Q and a third expansion chamber R) through a pIurality of (two pieces in this modality) bulkheads (hereinafter referred to as a first bulkhead 431 and a second bulkhead 432) and an end portion 41OA of the discharge pipe 410 penetrates the portion of the front wall 423 of the cylindrical main body 420 and is inserted into the cylindrical main body 420. 10 In the first bulkhead 431 located on the front side of the cylindrical main body 420, a cylindrical positioning element ( positioning) 435 penetrating this first bulkhead 431 and extending in the longitudinal direction of the main cylindrical body 420 is secured.

This cylindrical positioning element 435 is formed into a cylindrical shape 15 whose diameter is gradually reduced towards the side of the front wall portion 423 and the discharge pipe 410 is inserted into a front end portion 435A with the smallest diameter substantially without a free span and is joined by welding or the like.

Also, in a portion of the rear end 435B of that 20 positioning cylindrical element 435, the outer cylinder 43 constituting an outer box of the catalytic device 4 is fitted and joined by SIDING or the like.

The discharge pipe 410 has an enlarged diameter portion 41OB whose diameter is gradually widened backwards in the positioning cylindrical element 435 and the end portion 41OA 25 of that enlarged diameter portion 41OB is located at the rear of the element positioning cylindrical 435. That is, the end portion 41OA of the discharge pipe 410 is located at the rear of the securing portion 437 between the positioning cylindrical element 435 and the outer cylinder 43 and enters the outer cylinder 43. Also, the '30 41OA end portion of that discharge pipe 410 is formed with substantially the same diameter as that of the catalyst carrier 40 in the catalyst device 4 and is disposed close to the catalyst carrier 40.

The outer cylinder 43 of the catalyst device 4 extends along the longitudinal direction of the main cylindrical body 420, penetrates the second bulkhead 432 and is supported by the second bulkhead 432. In this case, as long as the catalyst device 4 is supported by the cylindrical element 5 positioning pump 435 and the second bulkhead 432, the lift resistance can be sufficiently guaranteed. Also, since the catalytic device 4 and the discharge pipe 410 are supported by the same cylindrical positioning element 435, the positional relationship between the catalytic device 4 and the discharge pipe 410 can be precisely defined. . A sound-absorbing material 402 made of glass or similar is disposed between the outer cylinder 421 and the inner cylinder 422 of the cylindrical main body 420, and the sound-absorbing material 402 is also disposed between a portion of the inner rear wall 424A and a portion of the outer rear wall 424B constituting the portion of the rear wall 424 and the inner side of a cylindrical body 425 covering the outer circumference of a rear pipe 445 penetrating the portion of the rear wall

424. The catalyst device 4 causes the end portion 41OA side of the discharge pipe 410 to communicate with the first expansion chamber P through a large number of the fine pores (penetration holes) 5 formed in the conveyor of the catalyst 40 and purifies the exhaust gas discharged from that end portion 41OA of the discharge pipe when it passes through the catalyst carrier 40. Here, the outer diameter of the catalyst device 4 is formed wider than the outer diameter of the end portion 41OA of the discharge pipe and the end portion 41OA of the discharge pipe and the conveyor of the catalyst 40 are positioned substantially coaxial by the cylindrical positioning element 435. In this way, the discharge gas discharges - cattle of the end portion 41OA of the discharge pipe can be induced to enter the catalyst carrier 40 efficiently and is induced to flow into the first expansion chamber P .

Also, in the second bulkhead 432, a first communication pipe 441 and a third communication pipe 443 penetrate and are fixed in a displaced position of the catalyst device 4, while in the first bulkhead 431, a second communication pipe 442 penetrates and 5 is fixed in a displaced position of the positioning cylindrical element 435. The first communication pipe 441 makes the first expansion chamber P communicate with the second expansion chamber Q, while the second communication pipe 442 makes the second communication chamber expansion Q communicates with the third expansion chamber R.

Also, the third communication pipe 443 has one end through the second expansion chamber Q, penetrating the first bulkhead 431 and is open in the third expansion chamber R, while the other end crossing the first expansion chamber P and the rear barrel 445 connected to its rear end penetrates the rear wall portion 424 of the main cylindrical body 420 and makes the third expansion chamber R communicate with the space outside the exhaust muffler 400. In this exhaust muffler 400, the exhaust gas unloading discharge from end portion 41OA of discharge pipe 410 passes through catalytic converter 4 and flows into the first expansion chamber P in discharge silencer 400 as shown by an arrow in figure 22, inverts the its flow direction, passes through the first communication pipe 441 and flows into the second expansion chamber Q, reverses the flow direction again, passes through the second communication pipe communication 442 and flows into the third expansion chamber R and then reverses the flow direction again and passes through the third communication pipe 443 and the rear pipe 445 and is discharged to the outside.

Since the sectional area of that main cylindrical body 420 is formed more wide than the discharge pipe 410 inserted in that main cylindrical body 420, the exhaust gas is decompressed when it flows into each of the expansion chambers P to R.

Also, since the catalyst device 4 is arranged on the cylindrical main body 420 of the exhaust silencer 400, the layout space for the catalytic device

pain 4 is easily guaranteed.

Also, since the catalyst device 4 is coaxially disposed in the end portion 41OA of the discharge pipe 410, the exhaust gas discharged from the end portion 41OA of the discharge pipe 410 can be induced to flow into the catalyst device 5 4 smoothly without changing its flow direction.

Subsequently, catalyst device 4 will be described in detail.

The catalyst device 4 is constituted similarly to the catalyst device 1 shown in figure 2. That is, the catalyst device is provided with the catalyst carrier 40 constituted similarly to the catalyst carrier 10 in the catalyst device 1 and carrying a - catalyst having the function of exhaust gas purification, the holding mat (also referred to as a catalyst holding mat) 42 similarly constituted as the holding mat 12 (figure 2) and covering the outer circumference of the catalyst carrier 40 and the external cylinder 43 constituting similarly as the external cylinder 13 (figure 2) and retaining the catalyst carrier 40 through the retaining belt 42. The catalyst carrier 40 uses a honeycomb structural body in which the fine pores 5 extend along its axial direction formed in the alveolar state as a base material and carries a platinum catalyst, pa rhodium, rhodium and so on which decomposes the exhaust gas component into this base material similarly as the catalyst carrier 10 described above (figures 1 and 2) - that is, the catalyst carrier 40 functions as a catalyst three-way and removes hydrocarbon, carbon monoxide and nitrogen oxide 25 in the exhaust gas by platinum, palladium, rhodium and so on and by oxidation and reduction reactions.

Here, the sectional shape of the catalyst carrier 40, that is, the sectional shape of the honeycomb body is formed into a column shape (cylindrical shape) having a true circular section.

Other shapes including an oval shape can be used as the sectional shape.

Also, in the eleventh embodiment, a ceramic socket formed by a porous ceramic body having a porous structure is used as the honeycomb structural body.

In this way, all weight can be reduced when compared to the case using a honeycomb structural body made of metal and also, since porous ceramics are used, the interior of the surface area can be easily guaranteed and the catalyst can be 5 easily transported, which are advantages.

Here, as a preferred example of ceramic material to be used as the base material for the catalyst carrier 40, various heat-resistant ceramics including cordierite, mullite, alumina and alkaline earth metal carbide of silicon, silicon nitride or the like or similar substances can be used.

Also, the shape of the base material can be in any shape such as a powder, a granule, a grain (including a sphere), a pellet (including a cylinder and a ring), a tablet, a socket or the like and it is preferably an alveolar structure.

The solution for making the catalyst carrier 40 transport palladium, rhodium and patin is made by dissolving a compound containing these metals in a predetermined solvent.

Materials used to make transported palladium include nitrate salt, chloride, acetate salt, complex salt (palladium dichlorotetraamine or the like) or the like.

Also, the materials used to make the transported platinum include nitrate salt, chloride, acetate salt, complex salt (platinum dinitrodiamine, platinum trichlorotramine or the like) or the like.

Also, materials for making the rhodium carried by the catalyst carrier include nitrate salt, chloride, acetate salt, sulfate salt, complex salt (pentaaminachlorodrome, hexaaminarode or the like) or the like.

By adjusting the solution of these materials and impregnating the catalyst carrier 40 described above with this solution, the catalyst carrier 40 can be created to transport palladium, platinum and rhodium.

As the solvent, water or organic solvents can be used, however water is preferable in view of the solubility, ease of treatment of the residual solution, availability and so on.

Also, after the catalyst carrier is impregnated with the solution, by heating and drying the catalyst carrier to approximately 250 ° C, for example, palladium,

rhodium and platinum are transported by the porous structure of the catalyst 40 carrier and nitrogen oxides, HC (hydrocarbon), CO (carbon monoxide) and so on in the exhaust gas can be decomposed and purified. Depending on the required purification performance of the discharge gas 5, the catalyst can be constituted by making only one or two types of palladium, rhodium and platinum transported by the catalyst carrier 40. Alternatively, other than palladium, rhodium and platinum, a metal or a metal compound and so on functioning as a catalyst can be transported by the catalyst carrier

40. Retention mat 42 is formed by integrating ceramic fibers in a long mat state and it is wrapped around the outer surface of the catalyst carrier 40 similarly as retention mat 12. At one end of retention mat 42, a projection-shaped joining portion is formed, while at the other end, a recess-shaped joining portion is formed, and in this way, when the retaining mat 42 is wrapped around the catalyst carrier 40, the mat can be retained in the state in which the connecting portions B are interlocked and wrapped around the catalyst carrier 40. Also, since the retention mat 42 is a coIection in which the fibers intertwine, a large number of tiny free spans it is formed on the surface and inside. In this way, the holding mat 42 has a relatively high elasticity and has a high surface roughness and a relatively high friction coefficient on the surface. Here, the material of the retention mat 42 can be any one as long as it has thermal resistance and elasticity, and the integration of fibrous metals or glass magnets or the like can also be used in addition to ceramic materials such as alumina, mullite, cordierite, silicon carbide or the like. The outer cylinder 43 is formed cylindrically, and more specifically, as shown in figure 24, it has a larger diameter than the outside diameter of the exhaust pipe 410 and is formed longer than the catalyst carrier 40 and the conveyor retainer 42 in order to guarantee a portion fitted with the positioning cylindrical element 435 described above.

As the material of this outer cylinder 43, a metal with high resistance and high thermal resistance is used and a steel material such as stainless is used, for example.

The catalyst carrier 40 around which the retaining belt 42 is wrapped is fitted into the outer cylinder 43 and contained in the outer cylinder 43. In that case, provided that the retaining belt 42 is compressed between the outer cylinder 43 and the conveyor of the catalyst 40 in the compressed state, the holding force to retain the catalyst carrier 40 in the outer cylinder 43 is generated by an elastic force and a frictional force of the holding mat 42. Therefore, even if the outer surface of the conveyor of catalyst 40 is a ceramic surface with a relatively low friction coefficient, the holding force can be guaranteed using this holding mat 42. When the catalyst carrier 40 around which the holding mat 42 is wrapped is contained in the external cylinder 43, methods in addition to pressure adjustment, that is, potting or winding and tightening can be used, for example.

In the case of potting, the catalyst carrier 40 around which the holding belt 42 is wound is surrounded by split parts formed in order to divide the cylinder into a plurality of parts along the axial direction and the split parts are joined together to form the outer cylinder 43. Also, in the case of winding and tightening, a sheet material is wrapped around the catalyst carrier 40 around which the holding mat 42 is wrapped and the portions end of the sheet material are joined to form the outer cylinder 43. Here, the union of potting and winding and tightening is carried out by welding, adhering, screwing or the like.

In the eleventh embodiment, as shown in figure 22, the catalytic device 4 is supported by the positioning cylindrical element 435 that holds the discharge pipe 410 and the second bulkhead 432 and the end portion 41OA of the discharge pipe and the conveyor of the catalyst 40 are coaxially arranged and the end portion 41OA of the discharge pipe 410 is arranged close to the catalyst carrier 40. Also, the end portion of the holding mat 42 on the side of the discharge pipe 410 is arranged, as shown in figure 24, with displacement to the downstream side of the exhaust gas from the end portion of the catalyst carrier 40, so that the distance (axial distance Ll) between the portion end point 41OA of the discharge pipe and the catalyst carrier 40 is less than the amount of displacement (amount of decoction L2). The axial distance Ll is preferably approximately 3 to 7 mm and is set to 5 mm, for example.

The amount of displacement L2 is preferably approximately 5 to 20 mm and is adjusted to 10 mm, for example.

In some catalyst devices in which the catalyst is transported by the prior art catalyst carrier made of ceramic, for example, the ring of the end portion that applies a clamping pressure in the axial direction on the belt surrounding the outer circumference of the catalyst carrier it is arranged inside a metal container.

With this configuration, the ring provision of the end portion increases the number of components.

However, if the end portion ring is removed from this configuration, it is expected that the exhaust gas will be brought into contact with the belt and the configuration in which the influence of the exhaust gas on the belt can be reduced has been a priority.

In view of this problem, in the eleventh modality, the configuration with the purpose of providing a ceramic catalytic device that reduces the influence of the exhaust gas on the conveyor and can reduce the number of components is explained.

That is, as explained as the eleventh modality, in the catalyst device 4 supplied with the catalyst carrier 40 made of ceramic that transports the catalyst to purify the exhaust gas from the discharge pipe 410, the external cylinder 43 that holds that catalyst carrier 40, and the retaining belt 42 compressed between the catalyst carrier 40 and the outer cylinder

43, the end portion 41OA of the exhaust pipe 410 is disposed near the catalyst carrier 40. As mentioned above, with the configuration in which the end portion 41OA of the exhaust pipe is arranged near the catalyst conveyor 5 , the exhaust gas discharged from the 41OA end portion of the exhaust pipe flows into the catalyst carrier 40 barely expanding in the radial direction with respect to its flow direction as shown by the arrow in figure 24. As a result, corrosion of the holding mat 42 by the exhaust gas, ie corrosion of the holding mat 42 can be suppressed.

Even if the exhaust gas discharged from the end portion 41OA of the discharge pipe flows while expanding in the radial direction immediately after the end portion 41OA of the discharge pipe, provided that the outside diameter of the catalyst carrier 40 is formed wider than the outside diameter of the 41OA end portion of the discharge pipe, the discharge gas can be induced to flow into the catalyst carrier 40 without being brought into contact with the holding mat 42. Here, the axial distance Ll (see figures 22 and 24) between the end portion 41OA of the exhaust pipe and the catalyst carrier 40 is a distance separated by the linear expansion of the discharge pipe 410 in the longitudinal direction by the exhaust gas and is defined for the minimum distance - so that the exhaust pipe 410 does not touch the catalytic converter 40 even if the pipe is linearly expanded by the heat of the exhaust gas.

In this way, while the influence of the exhaust pipe 410 by thermal expansion on the catalyst carrier 40 is avoided, the end portion 41OA of the exhaust pipe and the catalyst carrier 40 can be placed closer together.

As mentioned above, according to the eleventh embodiment, since the end portion 41OA of the discharge pipe is disposed near the catalyst carrier 40, the influence of the discharge gas on the holding belt 42 (wind erosion of the loading belt) retention 42 or the like) can be reduced without disposing the prior art end portion ring covering the end portion of the retention mat.

Also, since the ring of the end portion is not arranged, the number of components can be reduced, the complication of the shapes of the component can be avoided and a simple configuration can be carried out.

Also, in the eleventh embodiment, since the end portion 41OA of the exhaust pipe and the catalyst carrier 40 are arranged coaxially close to each other, the exhaust gas from the end portion 41OA of the discharge pipe can be induced to flow into the catalyst carrier 40 more reliably, and the wind erosion of the holding mat 42 can be suppressed more reliably.

Furthermore, in the eleventh embodiment, since the catalytic device 4 and the discharge pipe 410 are positioned and supported by the cylindrical positioning element 435 supported by the first bulkhead 431, the end portion 41OA of the discharge pipe and the catalyst carrier 40 can be positioned precisely.

Therefore, the capacity of the catalyst can be used efficiently, the expansion of the diameter of the catalyst carrier 40 can be avoided, the size of the exhaust silencer 400 containing catalyst device 4 can be reduced and the freedom in the design of the shape of the muffler can be improved.

Also, since the end portion 41OA of the exhaust pipe is located closer to the conveyor side of the catalyst 40 than the clamping portion 437 between the positioning cylindrical element 435 that positions the discharge pipe 410 and the outer cylinder 421, the end portion 41OA of the exhaust pipe can be placed closer to the catalyst carrier 40. In this way, it is expected that the flow of the exhaust gas to the holding belt 42 will be reduced.

Furthermore, since the end portion of the retaining mat 42 in the exhaust barrel side 410 is arranged with displacement to the downstream side of the exhaust gas than the end portion of the catalyst carrier 40 and the distance Ll between the end portion 41OA of the exhaust pipe and the catalyst carrier 40 is less than the displacement amount L2, the catalyst carrier 40 can be placed closer to the end portion 41OA 5 of the exhaust pipe and the holding mat 42 can be separated from the end portion 41OA of the discharge pipe, so that the holding mat 42 can be protected and the reduction of wind erosion can also be expected.

This eleventh mode is just an example of configuration and is capable of several design variations.

For example, in the eleventh embodiment, the case in which the retaining mat 42 is wrapped around the outer circumference of the catalyst carrier 40 is explained once, but by increasing the thickness of the joined portion 42X by overlapping. at both ends of the holding mat 42, the catalyst carrier 40 is eccentric with respect to the outer cylinder 43 as shown in figures 25A and 25B.

Here, figure 25A shows the end portion 41OA of the discharge pipe in the exhaust silencer 400, the positioning cylindrical element 435 and the catalytic converter 4, while figure 25B shows a sectional view of the catalyst device 4. Also, in figure 25B, the reference letter Cl represents the center of the geometry axis of the catalyst carrier 40, the reference letter C2 represents the center of the geometric axis of the outer cylinder 43 and the reference letter L3. shows an eccentric amount.

In this case, if the end portion 41OA of the discharge pipe and the outer cylinder 43 are arranged eccentrically due to the restriction of the layout space in the exhaust muffler 400 or similar, it is possible to arrange the end portion 41OA of the pipe discharge valve and catalyst carrier 40, so that they are aligned coaxially only on the way to the winding of the holding belt 42. Also, in the eleventh embodiment, an example of application in the catalytic converter for a motorcycle is explained , but not limited to, the present invention can be applied to the catalytic device

mounted on a three-wheeled vehicle, a four-wheeled vehicle or an automobile or similar classified as a different ATV (all terrain vehicle) and purifying the exhaust gas from the exhaust pipe.

Claims (13)

1. Catalyst device (1), characterized by comprising: a catalyst carrier (10) which carries a catalyst having a discharge purification function, 5 an external cylinder (13) containing the catalyst carrier (1O ) and a belt (12) disposed between the catalyst carrier (10) and the outer cylinder (13), wherein a high friction portion (14) is disposed between the catalyst carrier (10) and the cylinder outer (13) in order to prevent movement »of at least one between the catalyst carrier (10) or the belt (12) and the high friction portion (14) is formed having the same catalyst as the catalyst carried by the carrier of the catalyst (10) adhered to the inner face of the outer cylinder (13). 2. Catalyst device (1) according to claim 1, characterized in that the high friction portion (14) is arranged in a region including at least any one portion in contact with a portion of the end of the mat (12) or its proximity to the inner face of the outer cylinder (13). 3. Catalyst device (1) according to claim 1, characterized by the fact that one end of the external cylinder (13) located on the downstream side with respect to the discharge gas flow is extended further away than an end portion of the mat (12) and the high friction portion (14) are formed in that extended portion. 4. Catalyst device (1), characterized by comprising: a catalyst carrier (10) that carries a catalyst having a discharge purification function, an external cylinder (13) that contains the catalyst carrier (10O ) and a belt (12) disposed between the catalyst carrier (10) and the outer cylinder (13), in which a high friction portion (14) is disposed between the catalyst carrier (10) and the outer cylinder (13) in order to prevent movement of at least one between the catalyst carrier (10) or the conveyor (12) and the high friction portion (14) is formed having the same catalyst as the catalyst transported within the carrier of the catalyst (10) adhered to the inner face of the outer cylinder (13). J 10 Catalyst device (1) according to claim 4, W characterized by the fact that The high friction portion (14) is arranged at least in part of the portion in contact with the mat (12) on the surface of the catalyst carrier (10). 15 Catalyst device (1) according to any one of claims 1 to 5, characterized in that the catalyst carrier (10) is formed by ceramic. 7. Catalyst device (1), according to claim 4, characterized by the fact that the high friction portion (14) is formed by having the catalyst also attached to the surface of the catalyst carrier (10) in a process in which the catalyst carrier (10) is induced to be transported within the catalyst carrier (10). Catalyst device (1) according to any one of the claims 1 to 7, characterized by the fact that at least part of the inner face of the outer cylinder (13), a predetermined material that can be oxidized more easily than that a stainless material in the exhaust gas of the internal combustion engine is disposed. 9. Catalyst device (1) according to claim 8, characterized by the fact that the predetermined material is a material in which the reaction of o- xidation progresses at a lower temperature than the temperature at which the stainless material is oxidized in the exhaust gas of the internal combustion engine. Catalyst device (1) according to claim 85 or 9, characterized in that the predetermined material consists of an SP material. Catalyst device (1) according to either of claims 9 or 10, characterized in that in the predetermined material, an additive material of the same position 10 as the material forming the mat (12) or a composition containing "a common element with the material is added e. the predetermined material is disposed in a position in contact with the mat (12) on the inner surface of the outer cylinder (13). y 12. Method of manufacturing a catalyst device (1), characterized by comprising: a first process for forming a assembly unit consisting of a ceramic catalyst carrier (10) carrying a catalyst having a function discharge purification system and a belt (12) wrapped around the external side of the fitter conveyor (10) that are contained in the external cylinder (13), a second process of inducing the adhesion of a catalyst having a discharge purification function inside the catalyst carrier (10) contained in the assembly unit and a region including at least any of a portion in contact with the belt end portion (12) on the inner face the outer cylinder (13) or its proximity and a third sintering process of the assembly unit in which the catalyst is induced to adhere. 13. Catalyst device (1), characterized by comprising: 30 a catalyst carrier (10) that carries a catalyst having a discharge purification function, an external cylinder (13) that contains the catalyst carrier (10) and a conveyor (12) arranged between the catalyst carrier (10) and the outer cylinder (13), in which a high friction portion (14) is disposed between the catalyst carrier (5) and the outer cylinder (13) in order to prevent movement of at least one between the catalyst carrier (10) or the mat (12), in a position in contact with the mat (12) on the inner surface of the outer cylinder (1 3), a predetermined material that can be oxidized more easily than a stainless material in a discharge gas .4 10 of the internal combustion engine is arranged and in the predetermined material, an additive material of the same composition as . the material that forms the mat (12) or a composition containing a common element with the material is added.